THE ANNALS OF UNIVERSITY “DUNĂREA DE JOS “ OF GALAŢI 63

FASCICLE VIII, 2007 (XIII), ISSN 1221-4590

TRIBOLOGY

Paper present at

International Conference on
Diagnosis and Prediction in Mechanical
Engineering Systems (DIPRE’07)
26 - 27 October 2007, Galati, Romania

THE RESULTED ROUGHNESS AT TURNING OF SOME

NON-METALLIC MATERIALS AND CORRELATION
WITH DURABILITY OF MACHINE CUT SURFACES
Ileana Cristina PASCU, Iulian POPESCU

University of Craiova, Faculty of Mechanics

i_pascu@yahoo.com

ABSTRACT
In this paper there are studied the results obtained at graphite and polyvinyl
chloride turning. Such pieces are used like loose parts or in subassemblies. The
final roughness of such pieces after processing and the influence of processing
parameters are evaluated. Thus, factorials experiments are used and non-linear
relations that take into consideration the cumulated influences of two factors on
roughness are obtained. The achieved results and final relations for Rz are
presented. Also, microscopically images of these surfaces for different cutting
workings are presented in this study.

KEYWORDS: Roughness, durability, turning, graphite, polyvinyl chloride.

1. INTRODUCTION A detailed work on surface roughness of a

Some tribological aspects proper for electrical
contacts that content graphite are studied in [6]. The
influence of roughness on the quality of electrical
contacts based on metal-graphite and bronze are
achieved here. Also, theoretical aspects and
experimental results are presented.
In [7] tribological aspects of Ag/Graphite/ Mo
composite are presented. Wear tests have been made
and wear diagrams for various conditions have been
presented. In [1] there are presented dissimilar
repairing processes for vault pipes of laminated
plastics, on working, through powered winding of
these with layers of others plastics. Here is essential
the roughness of pipe external surface after a lifetime,
a conditional roughness depending on the initial one.
Some aspects of surfaces wear of some pieces
based on thermoplastics materials, in contact with
steel pieces surfaces are presented in [2]. Also, the
wear diagrams and images obtained on microscope
are performed.
polymeric material (polymethylmethacrilate) is
presented in [9]. Images of surfaces on nano-metrical
level by some up-to-date apparatus supplied on
computer are performed.
In a study on duty cycle for a product [11] it is
presented economical factors, correlatives with
products durability, have the highest weight factor.
Aspects about retaining of worn products depends on
wear state of contact surfaces are performed.
The image of cutting processed surface for
various types of materials is evaluated in [10] by a
combined system based on the backscattering of real
surface and this covering with a very fine diamond
needle. The spatial image of surface and an
astatization of curve of surface shape in a certain
section is presented.
A new method for visualization of processed
surface for dissimilar materials [8] is based on
acoustical microscope. The image appears in sharp
relief with spatial and very clearly shapes. The
measuring system is very accurate.
64 THE ANNALS OF UNIVERSITY “DUNĂREA DE JOS “ OF GALAŢI
FASCICLE VIII, 2007 (XIII), ISSN 1221-4590
TRIBOLOGY
The visualization of concrete shape aspect for a
processed or wear surface is presented in [3] by
means of an apparatus based on an eidophor and
electron camera with variable position. Therefore, the
errors of shape with spotlighting of surfaces rounding
can be observed.
Some problems about the processing of some
polymeric materials with cutting tool of diamond
single crystal are presented in [4].
Physical phenomena that appear due processing
time presenting diagrams and micro-images are
studied.
Interesting shapes of processed surfaces by
ultra-precise fractionation of pieces based on crystals
of calcium fluoride are performed in [5]. The images
are on nano-metrical dimensions and roughness Ra
have values between 0.077 nm and 0.72 nm. The 3D-
images display such hills and valleys.
2. INFLUENCE OF ROUGHNESS ON
DURABILITY
Electrodes based on graphite have large
applications in metallurgy and electrotechnical
industry. Graphite is used in chemical industry and
light industry, too. Some of these pieces form
adjustments matching and so, the roughness has
influence on the adjustment accuracy and his
durability.
Due to graphite has low crushing and cross
bending strength, the micro-asperities of pieces in
contingence are used shortly enough and influence
the working life of that assembly.
For this reason, it is important to know the
relation between roughness and parameters of cutting
process for obtaining a suitable roughness in point of
durability, too.
The plastic materials have large applications in
various areas, especially in chemical industry, oil
industry, in plants for building, and so on.
But, plastics processing is restrained because of
some temperatures at which modifications of
physical, mechanical and chemical properties can be
appeared.
For this reason it is important to refer to these
phenomena at processing.
Usually, following techniques are used for
achievement pieces based on plastic materials:
- injection moulding: high productivity and
accuracy but needs expensive and intricate injection
moulds;
- extrusion: high productivity, tools at an easy rate
but low precision;
- hot moulding (in vacuum, pneumatically, dish):
common process, easy but expensive with
technological restraints;
- drill (centrifugally, compression, mixed with
extrusion): low productivity and restraint of shapes;
- casting: moderate casting moulds but workable
just for sheer forms.
Plastic materials processing by cutting requires
more particular elements than other materials cutting
because of the plastic materials properties. Otherwise,
some pieces of plastic materials do not require
cutting. But, cutting processing is necessary for
pieces with high accuracy, for those which small-
scale production (the injection moulds cost being
expensive) and for parts with intricate shapes that can
not be obtained only by injection or extrusion.
The following particular properties of pro-
cessing of plastic materials by cutting are referred to:
- a small modulus of plasticity and therefore the
fixing should be perform with smaller forces;
- possess plastic memory which means that
they have a high elastic recovery after cutting
edge of bit passing;
- small heat conductivity so the heat is most
absorbed by the cutting tool and only by above-
ground of plastic material piece;
- high thermal coefficient of expansion which
provokes modifications of dimensions and
increasing of abrasion with cutting tool;
- low heat distortion point which restricts the
parameters of cutting working.
At turning of thermoplastic materials (nylon,
polystyrene, polycarbonate, and so on) are used
brazed type carbide tools with γ very small, even
negative, with very properly pointed cutting edge of
bit (rn small): α = 10…150; χr’ = 120.
The plastic materials such polyvinyl chloride,
organic glass, capron, phenoplast, can be easy cheep
removing processed with cutting tools of high speed
steel.
The plastics materials such hyaline-hard-plastic
have more abrasive properties with higher content of
glass fibers. By these properties influence on tool
wear and rate of cutting.
Much abrasive dust comes off at cheep removal
process of these materials and they are necessary
additional devices for aspiration.
These particularities must be accounted at
estimation of time resistance for fits formed by pieces
based on plastic materials.
Also, for polyvinyl chloride small crushing and
cross bending strength are established. Thus the wear
is fact for clearance and medium adjustments
matching. Besides, for interference adjustments
matching the time reliability has a great significance
such for adjustments matching used on conduction
and gas under pressure delivery systems. In this case
the roughness is important for assurance of
underwriting compression.
3. ROUGHNESS AT GRAPHITE
TURNING
Splintering by turning of a graphite bar by
factorial experiments has been studied. The
experimental area is given in table 1 and factorial
executable program is presented in table 2.
 THE ANNALS OF UNIVERSITY “DUNĂREA DE JOS “ OF GALAŢI 65
FASCICLE VIII, 2007 (XIII), ISSN 1221-4590
TRIBOLOGY

Table 1. Coding of variables used for graphite

Parameters Levels
Real Encoded -2 -1 0 +1 +2
v, m/min x1 94 188 238 302 377
f, mm/rot x2 0.230 0.420 0.604 0.850 1.66
ap, mm x3 1 3 6 8 12

a) Sample 13 b) Sample 2 c) Sample 1

d) Sample 12 e) Sample 11 f) Sample 9

g) Sample 6

Fig.1. Micrographics of pieces based on graphite.

Table 2. Experimental program The established relations for roughness are:

Sample v f ap - for Rz;
1 188 0.420 3.00 function  - 673.7056+3.007  v+38.86109  f +
2 302 0.420 3.00 +146.9694  a p +0.9503  v  f- (1)
3 188 0.850 3.00
4 302 0.850 3.00 -0.37155  v  a p + 0.1713772  a 2p
5 188 0.420 8.00
6 302 0.420 8.00 - for Ra:
7 188 0.850 8.00 Function=1.547363-0.1017  v+(10.07874)  f=
8 302 0.850 8.00
9 94 0.604 6.00 =2.8106  a p +1.1024  10 -2  v  f+
10 377 0.604 6.00 +3.29397  10 -3  v  a p  (2)
11 238 0.230 6.00
12 238 1.660 6.00 -6.62602  f  a p +1.8206  10 -4  v 2 +
13 238 0.604 1.00
14 238 0.604 12.00 +23.81033  f 2 +(0.1713772)  a 2p
15 238 0.604 6.00
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FASCICLE VIII, 2007 (XIII), ISSN 1221-4590
TRIBOLOGY

For each sample the surfaces obtained after
turning have been studied on the microscope.
Some of these images having indicated the
number of respective sample too are presented in
figure 1. But, the detailed study is performed on the
basis of all images obtained at microscope.
Based on all images obtained on microscope,
the followings results are established:
- the surfaces obtained are non-uniforms, with
pulling out of material having many craters;
- the parameters of cutting process have a high
influence on roughness; for high advances of
tool or/and big cutting depths, the roughness is
insufficiently;
- for big rates of cutting, the roughness is
better;
- by comparative analysis between table 2 and
figure 1, the lumped influences of factor on
roughness can be observed;
- the marks of cutting edge tool can not be
observed therefore do not appear a certain
regularity of the feed marks which means that
the cutting is made like at grinding through
pulling away, not by geometrical generation.
In conclusion, the roughness at graphite turning
is non-uniform with many craters and pulling out of
material and the tool geometry has a great influence.
4. ROUGHNESS AT TURNING OF
POLYVINYL CHLORIDE
Different aspects of turning of polyvinyl
chloride have been studied.
Experimentally, a semi manufactured product
kind barrel with 130 mm diameter and 400 mm length
obtained by extrusion has been used.
A cutting tool of high speed steel with: αn = 250;
γn = 100; χr = 450; χr'’ = 550; λ = 150. Cooling fluid had
not used.
In table 3 the experimental field is presented
and in table 4 the factorial program is given.
Also, the values of calculated roughness with
relation founded (yc) and the measured roughness
with Schmaltz microscope (ym) and their difference
between these values are presented.
The relation obtained for roughness Rz is
following:
Rz = 6.15033+(-3.4609  10 -2 )  v+(3.09306)  f+
+(-8.97827  10 -2 )  a p +(1.79639x10 -2 )  v  f+
+(-5.76355x10-4)  v  a p +(4.985836x10 -5 )  v 2 +
+(-31.54834)  f 2 +(-0.22879)  a 2p
(3)
In figure 2 there are presented two from among
15 images obtained on microscope.
The study was difficult because the color of
material can not permit a better contrast. Besides, the
roughness scale is very closer, the measured values
varied between 1.23…3.85 μm, thus the discrepancies
are smaller. Generally, only by-pass channels appear,
with different pitches depending on feed.
The zones that have notations with pencil have
been photographed thus pencil marks clearly indicate
respective channels.

Table 3. Coding of variables used for polyvinyl chloride

Parameters Levels
Real Encoded -2 -1 0 +1 +2
n, rot/min x1 250 500 630 800 1000
f, mm/rot x2 0.118 0.125 0.146 0.208 0.46
ap, mm x3 0.5 1 1.5 2 2.5

Table 4. The experimental program and checking for expression obtained

Sample v f ap yc ym Difference
1 217 0.125 1.00 2.21 2.16 0.04588
2 347 0.125 1.00 1.58 1.32 0.25638
3 217 0.208 1.00 2.77 2.86 0.08852
4 347 0.208 1.00 2.33 2.21 0.12690
5 217 0.125 2.00 2.59 2.26 0.33385
6 347 0.125 2.00 1.88 1.23 0.65439
7 217 0.208 2.00 4.00 3.85 0.14409
8 347 0.208 2.00 3.49 3.36 0.12655
9 108 0.146 1.50 4.55 4.51 0.03955
10 434 0.146 1.50 2.65 2.99 0.33966
11 273 0.118 1.50 1.85 2.30 0.44601
12 273 0.460 1.50 3.61 3.62 0.01294
13 273 0.146 0.50 1.48 1.45 0.03071
14 273 0.146 2.50 2.61 3.03 0.42887
15 273 0.146 1.50 2.27 2.71 0.43479
 THE ANNALS OF UNIVERSITY “DUNĂREA DE JOS “ OF GALAŢI
FASCICLE VIII, 2007 (XIII), ISSN 1221-4590
TRIBOLOGY
a) Sample nr. 3.
b) Sample nr. 4.
Fig. 2. Micro-geometry for surfaces pieces
made by polyvinyl chloride.
Analyzing all images resulted on microscope,
the following conclusions can be established:
- the great influence on roughness has the feed: at
maximum feed the most coarsening surface is
obtained;
- with feed increasing the pitches between flutes
on piece are increasing;
- under figure 2 and table 4, the cumulated
influences of two factors on roughness can be
pursued;
- peak of prominences are flatted like depths of
contractions cavity, being generated “almost
geometrically” by cutting tool;
- plastic deformations at cutting of this material
are small, the final obtained roughness being close
of theoretical roughness.
Therefore, this material is easy to splintering,
with a roughness which can be with accuracy
calculated and that is advantageously at formation of
adjustments matching with high durability.
67
5. CONCLUSIONS
The roughness resulted at graphite and
polyvinyl chloride turning is important for evaluation
of durability at various adjustments matching.
At graphite turning the resulted roughness is
influenced by fractures of micro particles but the tool
geometry has no influence on it.
The turned surfaces on graphite parts have
many craters, non-uniform areas and have a
roughness more different than theoretical roughness.
At polyvinyl chloride (PVC) turning a very fine
roughness is established.
For polyvinyl chloride (PVC) the resulted
roughness is very close to theoretical roughness.
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