Int J Adv Manuf Technol (2006) 29: 118–128

DOI 10.1007/s00170-004-2483-y

ORIGINAL ARTICLE

G.P. Petropoulos · N.M. Vaxevanidis · C.N. Pandazaras · A. Antoniadis

Multi-parameter identification and control of turned surface textures

Received: 27 July 2004 / Accepted: 1 November 2004 / Published online: 16 November 2005
© Springer-Verlag London Limited 2005

Abstract A method for characterizing turned surface textures q1 , q2 parameters of the Fisher–Pearson distribution system
corresponding to varying cutting variables leading to differing r mean asperity curvature [µm]
profile shape is presented with emphasis on a global view of turn- Ra profile average height [µm]
ing machinability parameters. Through a multi-parameter ex- RDelA mean inclination of the asperities [◦ ]
perimental analysis of turned steel specimens, several standard- Rku kurtosis of the profile height distribution
ized parameters are developed. The ability of these parameters Rlr ratio of the real length to the horizontal length of the pro-
are tested to distinguish between different profiles in shape or to file [%]
identify some particular features with respect to cutting factors. Rp the distance between the maximum height and the mean
It is indicated that texture statistical functions and parameters are line of the profile [µm]
the most effective for relative discrimination and control. Based Rq standard deviation of the profile height distribution
on the results of this study, new maps for turned surface control [µm]
are developed. With regards to the variability of some of the pa- Rsk skewness of the profile height distribution
rameters at different surface measuring sites, it is evident that the Rsm mean spacing of the asperities at the centre line [µm]
amount of scatter is lower when cutting factors offer regular chip Rt maximum profile height [µm]
formation. v cutting speed [m/min]
β auto correlation length [µm]
Keywords Chip formation · Metal machining · λa mean wavelength of the profile irregularities [µm]
Surface texture parameters · Surface typology · Turning µ mean value of the log-normal distribution
σ standard deviation of the log- normal distribution
Nomenclature µ̂ mean estimator of a distribution
ŝ standard deviation estimator of a distribution
a, b parameters of the beta distribution
f feed [mm/rev]
m number of peaks in the profile 1 Introduction
n(0) number of intersections of the profile with the mean line
Metal cutting operations are a vital part of the manufacturing
G.P. Petropoulos (u) · C.N. Pandazaras industry, and the prediction or control of relevant response vari-
Department of Mechanical and Industrial Engineering, ables (e.g. surface texture and dimensional accuracy, cutting
University of Thessaly,
Pedion Areos, 383 34 Volos, Greece
forces, tool wear and tool life) attracts particular interest. One ba-
E-mail: gpetrop@[Link] sic machinability parameter is surface texture, which is closely
Tel.: +302421074064 associated with the quality, reliability and functional perform-
Fax: +302421074050 ance of components.
N.M. Vaxevanidis The various manufacturing processes applied in industry pro-
Hellenic Airforce Academy, duce the desired shapes of the components within prescribed
Dekelia Air Force Base,
Attica, Greece
dimensional tolerances and surface quality requirements. There-
fore, any proposed description of a technological surface should
A. Antoniadis take into account the features of the profile imparted by the ma-
Department of Natural Resources & Environment,
Technological Educational Institute of Crete, chining process performed. This is a crucial point because the
3 Romanou str., 73133 Chania, Crete, Greece process can be controlled through surface texture recognition,
 119

and also be used to generate suitable profiles for tribological selection exist [9–11]. These limitations are neglected by the
functioning. systems of surface classification and typology proposed in the
In usual industrial practices, roughness is evaluated by pro- literature on the premise that every particular machining opera-
file amplitude parameters such as Ra , Rt etc., which do not tion produces characteristic surface profiles [12, 13]. Surfaces of
provide information on the shape of the profile. Characteristics components machined under conditions leading to the aforemen-
like inclination and curvature of the surface roughness asperi- tioned chip formation modes may experience contact, and the
ties, “emptiness” or “fullness” of the profile, distribution of the surface texture characteristics are of primary concern for practi-
profile material at various heights are registered in the profile cal reasons of control and classification.
shape. The essential tribological aspects (e.g. friction, wear, state The aim of this study was to investigate into the topography
of lubrication) are highly dependent on profile shape [1–6]. In of turned surfaces processed under cutting factors with the ob-
this regard, the characterization of machined surface shapes is jective of identifying differing profile forms for practical reasons
necessary, and this can be achieved through multi- parameter to- of control and classification, or to developing simulation models
pography analysis. The main goal should be a proper texture and surface functioning. Specimens of Ck60 steel were turned
shape classification with the aid of statistical or random process under the proper cutting factors selected to achieve representa-
analysis, which has been referred to as the “typology” of surfaces tive surface patterns for each case considered.
since the 1960’s.
More than one hundred parameters have been proposed in
the literature, owing to the fact that a real profile shape is usu- 2 Analysis – experimental procedure
ally very complicated, and the functional requirements for the
components are very high in today’s industry [1, 7]. 2.1 Presentation of the profile measures used
The basic geometrical properties of the profile providing as-
pects of the shape are: The following parameters, parameter ratios and functions are
proposed and/or established to be sensitive in profile shape [12–
• Periodicity (periodic, random, mixed).
16]. They are briefly discussed in view of their distinctive power
• Form of the asperities (spiky, bumpy).
and tribological significance.
• Fullness or emptiness of the profile (more material or void).
• Multi-stratum surfaces related to the former two character-
2.1.1 Arithmetic amplitude parameters
istics (e.g. plateau honed surface texture with broad smooth
peaks and “rough” valleys [8]). These parameters cannot be considered alone, as they do not give
Turning is a widespread cutting process in industry, producing evidence about the shape of the profile. Instead, some combined
various texture shapes according to the cutting conditions em- ratios have been proposed, as follows:
ployed. Also it is a reference process, characterized by simple a) Ra /Rq : for the extreme theoretical cases of a sinusoidal and
kinematics and cutting tool geometry, and there is plenty of data a random profile conforming to the Gaussian distribution this
available in literature and databases. ratio takes the values 0.9003 and 0.7979, respectively; this
An arc chain surface pattern is typical for turning, but sig- ratio is simply indicative.
nificant deviations appear due to irregular chip formation phe- b) Rp /Rt : provides only general information on the “emptiness”
nomena, namely built-up edge, discontinuous chip, very low feed or “fullness” of the surface, and is related to skewness of the
rates, chatter, and intense tool flank wear; a general overview of profile height distribution
these sources is given in Fig. 1. These phenomena occur many c) K : is called solidity surface ratio, which is defined as K =
times, especially when limitations in productivity or in material (Rt − Rp )/Rt and is associated with skewness.

Fig. 1. Causes for irregular chip forma-

tion in cutting
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2.1.2 Space parameters give functional descriptions by the “Rk ” parameters (ISO
13565-2:1997).
a) Sm : a characteristic magnitude in periodic profiles (e.g. turn-
ing, milling), where it corresponds to the feed rate value c) Autocorrelation function and autospectrum
employed. • The profile autocorrelation function permits the qual-
b) λa : gives relevant information with Sm . It can be used as itative discrimination of periodic and random compo-
a general measure of the mean distance of asperities on ran- nents. The first attempt towards surface typology made
dom profiles. by Peklenik [18] defined five different autocorrelation
c) n(0): detects existing periodicity of the profile without pro- forms, with the extreme cases corresponding to sinu-
viding further information. soidal and white noise, respectively.
d) m: is correlated with n(0) and directly to the machining The autocorrelation length β∗ expresses the minimal
process. distance between profile characteristics of different
All three aforementioned parameters describe the number of origin.
micro-contacts from the tribological standpoint. • The spectral density function, or autospectrum, enables
the quantitative assessment of the various profile compo-
nents, periodic and random, and is the Fourier transform
2.1.3 Hybrid parameters
of the autocorrelation function. Strongly periodic pro-
a) ∆a : is possible to characterize the machining process and is files, for instance, are characterized by the fundamental
affected by the machining conditions, but does not determine component (at the feed value), followed by a series of
the profile shape sufficiently. higher harmonics.
b) r: is affected to a similar degree by the machining process, In Fig. 2 parameters and functions that are sensitive to profile
but does not describe particular profile features. form, according to the previous discussion, are outlined.
c) Rlr : the real profile length to evaluation length ratio is con-
nected to the profile openness and controls the corrosion 2.2 Experimental procedure
resistance [17]; by definition, it is proportional to ∆a .
All these parameters, however, may describe indirectly the shape In brief, the cutting factors applied and the materials used were:
of the profile peaks. a) The cutting conditions employed:
Cutting speed, v [m/min]: 10–185.
2.1.4 Statistical parameters Note: For the facing modes – in-feed turning (IFT) and out-
feed turning (OFT) – with constant spindle rotational fre-
a) Profile height distribution quency, the above cutting speed values were considered to be
• The form of this statistical function is very important as the maximums.
it is sensitive to the geometric features of the surface and Feed rate, f [mm/rev]: 0.05, 0.08, 0.10, 0.16, 0.20, 0.24,
to their variation. Multi-parameter statistical systems like 0.32, 0.40, 0.50, 0.60.
log-normal, beta, and Fisher–Pearson are used to model Depth of cut, a [mm]: 0.5.
a variety of profile shapes and could contribute to any b) The carbon steels used as workpiece materials were: St37,
acceptable typology of machined surfaces [2, 12]. Apart St60, C35, Ck45, Ck60 and stainless 316.
from the shape of the distribution, the corresponding sta- c) A sintered carbide insert P10 was used as the cutting tool.
tistical moments are evaluated: d) Dry cutting was used throughout.
The standard deviation σ is equal to the Rq parameter. The individual cases of chip formation that will be presented next
The third and fourth order moments – skewness and kur- correspond to the following cutting factors:
tosis – express geometric and physical features of the I) built-up edge: v = 25 m/min, f = 0.32 mm/rev, a =
surface, respectively. The skewness controls the amount 0.5 mm;
of existing material in the surface against voids. Kurtosis II) discontinuous chip: v = 5 m/min, f = 0.32 mm/rev, a =
defines the sharpness of the peaks of the asperities. Low 0.5 mm;
kurtosis values correspond to broad tips, whereas the op- III) very small chip thickness effect: v = 125 m/min, f =
posite characterizes sharp “hills”. 0.06 mm/rev, a = 0.5 mm;
b) Bearing area or Abbott curve IV) chatter: (the tool was excited in vibration by an abrupt vari-
This is equivalent to the cumulative probability of the ation of the spindle frequency), f = 0.32 mm/rev, vmean =
profile heights and is directly related to the surface tri- 125 m/min, a = 0.5 mm;
bological behaviour, and particularly, with the real con- V) severe tool wear (flank wear land width B=0.7 mm accom-
tact area, asperities strength, and wear. The bearing area panied by nose wear not measured):
curve has been widely used in recent studies, and with v = 125 m/min, f = 0.32 mm/rev, a = 0.5 mm; and
the introduction of a relatively new standard, it can eas- VI) the regular pattern (pure arc chain shape): v = 125 m/min,
ily distinguish between random and periodic profiles and f = 0.32 mm/rev, a = 0.5 mm; the latter is clearly periodic
 121

Fig. 2. A set of parameters and functions used or

proposed to controlling profile shape

of an arc-chain form and is achieved at moderate to high a, b: parameters of the beta amplitude distribution, and k:
feeds, high cutting speeds and negligible tool wear (nose or parameter of the Fisher–Pearson amplitude distribution.
flank). Random process parameters: Power spectrum (PS) of the profile
and the autocorrelation length β.
The cutting speed values for surfaces I and II and the feed for
Fractal geometry parameter: Fractal dimension D, which is cal-
surface III were selected from a wider range and correspond to
culated through the structure function method [19].
the most unfavourable cases in terms of the amplitude parameters
Ra and Rt (both represent maximum values) for the combination
of the workpiece and tool materials selected, in order to obtain
representative corresponding surfaces. 4 Results and discussion
Discrimination of the profiles

3 Surface texture analysis Two axes are considered in the analysis of the experimental
results: first, the comparison between the irregular types; and
A multi-parameter texture analysis was applied using standard- second, the distinction between them and the regular surface
ized (ISO 4287:1997) and other statistical and fractal functions. texture [20]. The selected parameters mean values are listed in
Surface profile measurements were conducted axially (the Table 1. (The Latin numbers in the first column refer to the chip
direction of the superposition of kinematics and natural rough- formation mode).
ness) with a sample size N = 40 using a skidless pick-up. In the case of the built-up edge, the texture is distorted with
Then, a multi-parameter surface texture analysis was applied via respect to the arc- chain form, as shown in the power spectrum.
Talyprof software. The 2D parameters selected were: Waviness takes a high value and the profile possesses significant
Amplitude parameters: Ra : central line average, Rt : maximum “openness”, as indicated by the high Rlr . Similar characteris-
peak to valley height in the evaluation length, Rp : maximum tics are revealed in the profile corresponding to discontinuous
height of the profile above the mean line, Rv : maximum chip. Considering the very small chip thickness phenomenon, the
depth of the profile below the mean line, and Wa : waviness profile is also distorted and exhibits small Rlr and negative skew-
amplitude average. ness. On the chatter marked-surface, waviness is higher than
Spacing parameter: Rsm : mean spacing between profile peaks at roughness, and the skewness takes the highest positive value. The
the mean line. profile generated by the worn tool appears less distorted than in
Hybrid parameters: RDelQ : quadratic mean of all local slopes, the former cases, and shows high kurtosis.
and RLr : the ratio of the developed length and the horizontal It is obvious that the amplitude parameters Ra , Rt , Rp , and
length of the profile. Rv by themselves, cannot characterize the profile shape. The ra-
Statistical parameters: Rsk : skewness of the amplitude distribu- tios Rp /Rt or Rv /Rt give the same information as Rsk , so they
tion curve, Rku : kurtosis of the amplitude distribution curve, are neglected. The Rsm value, theoretically, must be close to the
122

Table 1. Mean values of the used surface texture parameters in all the cases considered

Ra Rt Rp Rv Rsm RDelQ Rlr Wa /Ra Rsk Rku Beta Pearson Ra /Rq β D

[µm] [µm] [µm] [µm] [µm] [◦ ] [%] a b k [µm]

I 10.1 77.6 46.4 31.2 280 17.7 104.5 0.8 0.4 3.2 4.3 6.5 0.03 0.86 77 1.10
II 6.8 51.6 27.1 24.5 224 18.5 104.9 0.9 0.2 3.3 4.6 4.2 0.01 0.78 181 1.15
III 0.7 4.5 2.1 2.4 56 5.4 100.5 0.3 −0.2 3.1 3.8 3.6 0.0001 0.76 12 1.35
IV 7.5 50.7 30.7 20 247 10.9 101.3 3.0 1.1 3.7 2.8 4.2 0.17 0.79 67 1.12
V 10.7 56.6 28.6 18 312 11.1 101.6 0.2 0.9 3.0 1.2 2.6 0.14 0.79 60 1.21
VI 7.3 33.1 21.8 11.3 337 11.4 101.7 0.05 0.8 2.6 0.9 1.8 0.20 0.81 71 1.10

feed employed, but this is true only for the regular profile. The trum. Fractal dimension D takes on the highest values in the case
RDelQ and Rlr values appear high in the cases of the discontinu- of very low feeds due to the higher “complexity” of this profile.
ous chip and built-up edge formation. In all the cases of irregular Therefore, turned profiles can take extreme shapes, which deviat-
chip formation, the amplitude of waviness is significant as it indi- ing greatly from the theoretical periodic form. The profiles in the
cates the vibration generated by the cutting process; as expected, aforementioned cases of representative turning factors, together
it is much more pronounced for the surface with chatter marks. with power spectra and amplitude distribution models, are illus-
The forms closer to the regular ones show a high positive skew- trated in Figs. 3 to 8. The profiles are unfiltered from waviness
ness combined with kurtosis values lower than three. The beta to show the integrated textures. The degree of discrimination
and Fisher–Pearson parameters take quite different values at dif- achieved via the selected parameters is presented in Table 2.
ferent cases, and in this way they are distinctive. Additionally,
these parameters are able to identify different texture shapes. The Development of new charts
autocorrelation lengths are closely related to the Rsm spacing pa-
rameter. The power spectrum provides a qualitative distinction The results are interpreted in the form of charts that incorporate
between the periodic and the random profile components, but it is selected distinctive parameters. They will be compared to the rel-
difficult to define a suitable quantitative criterion. We found that evant “classical” charts.
a possible criterion to characterize the regular form could be the In Fig. 9a, the kurtosis and skewness of the measured surfaces
ratio of the fundamental to the first harmonic present in the spec- are shown. A cluster of points appears, since kurtosis and skew-

Fig. 3. Surface profile, power

spectrum, beta distribution
and Pearson distribution
curves for built-up edge for-
mation
 123

Fig. 4. Surface profile, power

spectrum, beta distribution and
Pearson distribution curves for
discontinuous chip formation

Fig. 5. Surface profile, power

spectrum, beta distribution and
Pearson distribution curves at
a very low feed rate value

ness are not interrelated [4], but they can fix the boundaries of regular chip formation. We compare this chart to a relevant chart
surface textures in view of shape for a wide range of cutting con- taken from [12], which is presented in Fig. 9b. It is evident that
ditions employed. The area with a high concentration of values, this chart is bounded by values over the ranges Rsk : 0.2–1.0, and
located at the lower-right portion of the diagram, corresponds to Rku : 1.9–3.5. The comparison is limited: these values represent
124

Fig. 6. Surface profile, power

spectrum, beta distribution and
Pearson distribution curves
under chatter conditions

Fig. 7. Surface profile, power

spectrum, beta distribution and
Pearson distribution curves
under severe tool flank wear

surfaces turned at low feed rates; in this case, the textures are dis- tered, and compared to the Whitehouse beta function typology
torted and are not purely periodic, as aforementioned. (Fig. 9d), the range is wider due to the fact explained before. The
A chart representing the parameters of the beta statistical diagram for the log-normal distribution parameters is presented
function is illustrated in Fig. 9c. Here, the values are less scat- in Fig. 9e, where the points are almost uniformly distributed and
 125

Fig. 8. Surface profile, power spec-

trum, beta distribution and Pearson
distribution curves for the case of
regular chip formation

Fig. 9. (a) Kurtosis against skewness chart; (c) beta

function parameters chart; (e) Log-normal parame-
ters chart; and the relevant charts according to [12]
or [21] (b, d, f respectively)
126

Table 2. Surface texture characterization through the parameters considered:

(1) between irregular and regular surfaces, (2) among special irregularities

Parameter Distinctive
1 2

Ra + −
Rt + −
Ra /Rq − −
Rsm + −
Rsk + +
Rku + +
RDelQ + +
Rlr% + +
Power Spectrum + −
Wa /Ra + +
Beta parameters + +
Pearson parameters + +
Auto correlation length β + − Fig. 10. Pearson parameters chart
Fractal dimension D + +

posed surface texture parameters exhibit when measurements are

made on different locations of the surface is not only related to
the whole regime appears expanded, compared to a previous ap- the experimental error, but also to the degree of homogeneity
proach [21] (Fig. 9f). of the texture, which in turn depends on the machining condi-
Fisher- Pearson parameters-based approach is proposed, and tions [22–24]. The standard deviation of average estimators of
the corresponding chart is shown in Fig. 10. It resembles the the distributions is regarded as the measures of variability along
beta function, as expected, but it may more explicitly distinguish with the relevant skewness and kurtosis values for the surfaces
different texture shapes. Thus, it could be considered as a sat- studied. Table 3 presents the variability of some roughness pa-
isfactory method towards the desired process identification. The rameters for some of the surfaces studied.
presented data is representative for a wide range of turned metal With few exceptions, all the parameters exhibit less dis-
surfaces encountered in practice, but is certainly not exhaustive. persion, and the relevant distributions are closer to the nor-
The charts could be modified yet again if worn tools are used and mal for the “regular” surface (VI). Where the values of pa-
are considered at different stages of wear, and if special turning rameters are widely scattered, they apparently need a larger
versions are performed. sample size for their determination. They may even be “non-
measurable”, and consequently fail to describe particular surface
Variability of the profile parameters for turned surfaces characteristics.
In Fig. 11, an example of the variability of Rsk , a parame-
It is well known that roughness possesses a stochastic charac- ter that is, by definition, sensitive to inordinate surface features,
ter that relates to both the shape of individual profiles and their is illustrated for cases of very small feed and the regular chip
repeatability over the surface. The amount of scatter that the pro- formation.

Table 3. Statistical moments and parameters

of the selected surface roughness parameters Ra RDelQ
variation – I: discontinuous chip, II: built-up ŝ/µ̂ sk ku a b ŝ/µ̂ sk ku a b
edge, III: very small feed rate, VI: regular
chip formation (where ŝ/µ̂ is the standard
deviation to average estimators, sk is the I 0.094 −0.04 −0.63 1.2 1.5 0.075 0.04 0.12 2.0 2.0
skewness of the distribution, ku is the kurto- II 0.103 0.57 0.35 1.3 1.9 0.052 0.59 0.09 1.6 2.3
sis of the distribution, and a and b are beta III 0.052 0.22 3.00 4.0 3.3 0.034 −2.97 14.70 5.5 1.9
function parameters) VI 0.020 0.97 1.15 1.2 2.3 0.014 0.03 − 0.52 1.4 1.3

Rsm Rsk Rku

ŝ/µ̂ sk ku a b ŝ/µ̂ Sk ku a b ŝ/µ̂ sk ku a b

I 0.151 1.10 1.89 1.4 2.9 0.618 0.33 − 0.04 1.8 2.3 0.117 0.65 − 0.23 1.3 1.7
II 0.079 −0.29 − 0.25 1.5 1.2 0.252 −0.67 − 0.02 2.0 1.4 0.107 1.50 3.06 1.4 3.0
III 0.047 1.47 3.57 1.2 3.0 6.620 5.11 30.55 1.5 6.0 0.571 5.94 36.58 0.1 1.4
VI 0.042 −3.13 10.78 1.7 0.2 0.066 0.34 − 0.77 1.1 1.2 0.047 0.57 − 0.53 0.9 1.2
 127
Fig. 11. Histograms of the distributions of
the surface roughness parameter Rsk and the
corresponding beta function models (a and b
– the beta function parameters)

7. These results may contribute to the introduction of suitable

5 Conclusions texture oriented criteria, for cases where the selection of cut-
ting conditions is questionable [9]. It would also be interest-
1. Compared to the regular ones possessing an arc chain shape, ing to introduce 3D profile parameters in a future research,
distorted patterns constitute a common characteristic of the to examine whether they achieve a more definite distinction
turned profiles for cutting factors, which leads to irregular among the various turned profiles.
chip formation (as was expected). Classical amplitude pa-
rameters, such as Ra , Rt , etc., only provide general state-
ments. The deviation of the asperities mean spacing Rsm
from the corresponding feed rates can be discriminative, but References
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