Proceedings of the 11th WSEAS International Conference on Automatic Control, Modelling and Simulation

Simulation of Cylindrical-Face Milling and Modeling of Resulting

Surface Roughness when Machining Polymeric Composites
MIHAIELA ILIESCU1, PAULINA SPNU1, MAGDALENA ROU1, BRINDU COMNESCU2,
1
Manufacturing Department,
1
POLITEHNICA University of Bucharest, 2OPTOELECTRONICA S.A. Company
1
Splaiul Independenei no. 313 Street, 2Atomitilor nr. 409 Street, Mgurele
ROMANIA
iomi@clicknet.ro, http://www.pub.ro; brindus@optoel.ro, http://www.optoel.ro
Abstract: - Polymeric composites materials have been developed to a high extend, lately, because of their very
important and special characteristics. Once obtained, parts made of these materials type, often need machining
and milling represent an efficient procedure. Simulation of cylindrical-face milling process enables
determination of possible errors in cutting tools trajectory while mathematical models of resulting surface
roughness allow estimation of this micro-geometrical precision parameter values.
Key-Words: - milling, process, simulation, regression models, surface roughness.
Some of them can be mentioned as: the nature and
structure of component elements, reinforcing
elements disposal into the matrix, obtaining
procedure of the rough/final composites part, cutting
tools
characteristics,
machinig
procedure
parameters values, etc.
Usually, polymeric composites materials
machinability is classified into four groups: good,
medium, difficult, very difficult [7]. There is only an
overall view, without specification of the considered
parameter, meaning, surface roughness, machining
forces values, cutting zone temperature, cutting tool
durability, etc [5].
Some widely used maching procedures, can be
stated to be conventional ones milling, drilling,
turning or / and non-conventional ones
electroerosion, laser, ultrsounds etc.
Simulation of cutting tool trajectory is often
usefull, as enables avoiding possible errors in the
shape of machined surfaces. There are many
softwares to be used for this kind of simulation, the
best being the one specific to CNC machine-tool
where machining procedure is performed.
Surface roughness represents an important factor
when evaluating one materials machinability,
because of its role in part good functioning behavior.
Regression model is worth to be determined as, it
represents an accurate way of estimating roughness
values, when some important machining parameters
are set to their optimum values [2]. Reversing, when
a certain surface roughness has to be obtained, the
model enables determination of any machining
parameter value, among the considered ones, so as
to get the required roughness value.

1 Introduction
Composite material referrs to two, or more
materials, macroscopically combined, so as to result
an useful new material. Many times, composites
perform component elements best charactersitics,
even, characteristics that neither of the elements
have [8].
One material, meaning the basic one, is
represented by the matrix (metalic, polymeric or,
ceramics) while the other(s) is the reinforcing
element (ceramics, glass, carbides, wood, paper
etc.). The most important aspect to be considered,
when choosing composite elements, has to be the
type and the strength of the bond between matrix
and reinforcing element, when referring to their
intarface [1].
Polymeric matrix composites offer very good
characteristics, when comparing to classic materials,
some of them being: high resistance / weight ratio
values; high environment and/or chemical agents
corosion resistance; high vibration softening ability;
low thermal expansion coefficient values; good
machinability at low temperature, below 200 C, etc.
There are many procedures of obtaining polymeric
composites materials parts, such as manually,
sparying, resin transfer molding, injection molding,
extrusion, etc. Consequently, various shapes and
dimensions products are obtained, sometimes
meeting their specifications, some other times
furfther machining being necessary.
Machinability of polymeric composites has been
studied from their very early appearance [6] and,
resulted to be influenced by a large number of
factors.

ISSN: 1790-5117

219

ISBN: 978-960-474-082-6

Proceedings of the 11th WSEAS International Conference on Automatic Control, Modelling and Simulation

This paper presents some theoretical and

experimental research on glass fiber reinforced
polymeric composites machinability in milling. The
studied aspect is that of resulting surface roughness,
evaluated by Ra parameter (average value, DIN
4768) when cylindrical-face milling a romanian
made polymeric composite - random glss fiber
reinforced. Similar studies were not found, into the
specific literature studied.

2 Cylindrical-Face Milling Simulation

Nowadays, more and more machining procedures
are carried on computer aided, CNC (Computer
Numerical Control) machine-tools. So, accurate,
complex, various shapes and dimensions of the
resulting surfaces can be obtained.

Fig. 2 Cutting tool trajectory simulation

An image of the cutting tool trajectory

simulation, is shown in figure 2.
Considering all the above mentioned aspects,
there has been done simulation of the cylindricalface milling process. As the target of reseearch
presented by this paper is to model surface
roughness values, cutting tool machining trajectory
has been considered as simple as possible. Also,
taking into account the real samples shape, a
paralelipiedic part cylindrical-face milling process
has been simulated.
As experiments involve lot of machined
material, and, real samples availability is limited, the
milling process was carried on all their side faces.

There have been considered Isel-automation

manufacturing systems which, mainly, consist of
three parts [9]:
isy CAM software operating under Windows,
enabling Isy-CAM CAD part (for designing and
modeling parts 2D or, 3D) and Isy-CAM CAM part
(for machining on CNC machine-tools with 3, 3.5 or
5 axes);
ProNC software modern interface for
operating and programming of machine-tools,
according to isel PAL or, DIN 66025 specifications,
CNC EUROMOD basic units, used for parts
machining and/or control, with rigid and low
vibration structure see figure 1 [10].

a.

b.

Fig. 1 CNC EuroMod-P basic unit [10]

Fig. 3 Isy-CAM CAM software simulation phases

ISSN: 1790-5117

220

ISBN: 978-960-474-082-6

Proceedings of the 11th WSEAS International Conference on Automatic Control, Modelling and Simulation

Table 1

Fig. 4 Part at the end of simulation process

Pahses of cylindrical-face milling simulation

process, done with Isy-CAM CAM software, are
presented in figure 3 (a. and b.) while, the part at
end of simulation process can be seen in figure 4.

(1)

where:
zj , j = 1, 2, ., k represents the process
independent variables (controllable inputs);
Y the process dependent variable (output);
- the type of dependence relation.

x3

x4

1
2
3
4
5
6
7
8
9
10
11
12

-1
+1
-1
+1
-1
+1
-1
+1
0
0
0
0

-1
-1
+1
+1
-1
-1
+1
+1
0
0
0
0

-1
-1
-1
-1
+1
+1
+1
+1
0
0
0
0

-1
+1
+1
-1
+1
-1
-1
+1
0
0
0
0

The independent variables studied were:

- cutting speed, v [m/min];
- cutting feed speed, vf [mm/min];
- axial cutting depth, aa [mm];
- radial cutting depth, ar [mm]

In order to determine optimum type, there must

be established the values and variation field of each
input - both real z j and coded x j , as well as

( )

x2

Experiments were carried out on composite samples

made of AROPOL S 599 polyester resin and
EC 12-2400 glass fibers. The samples were made at
S.C. TURINGIA S.R.L., a certificated company in
composites manufacturing, and they were plates of
200 200 10 (mm) with Conformity Certificate
see figure 5.
As mentioned above, the reinforcing element is
represented by glass fibers, more specifically,
random oriented short glass fibers, 20% content .
The cutting tool are special ones, FGR-7M EDP
no. 83038 their image being shown in figure 6

When machining, optimum results can be obtained

if there are quantitative data, expressed [5] as
multivariable process function:

x1

4 Experiments

3 Experimental Research Methodology

Y = z1 , z 2 ,..., z j ,..., z k

Exp.
No.

Regression coeficients number: 5

Design of experiments, P2.1 structure

( )

the experiment design type that fits best [3].

Their real and coded values are presented in

Table 3.

When zj has minimum or, maximum real value,

the xj coded value is -1 (low level) or, respectively,
+1 (high level). Each considered variable has three
values (minimum, maximum and medium) within
the experimental considered region, the medium one
for zj representing the geometrical mean of its
minimum and maximum values. Consequently, the
xy medium level is considered to be of 0 value.
There have been considered a P2.1 experiment
design type, its structure being presented in Table1.
The dependence relation considered is the
regression model:

Fig. 5 Samples before experimenting

Y=

a
A0 x1 1

a
x22

a
x3 3

a
x4 4

(2)

Fig. 6 Glass fibers polymeric

composites milling tool

which get to linear one, by logarithm.

ISSN: 1790-5117

221

ISBN: 978-960-474-082-6

Proceedings of the 11th WSEAS International Conference on Automatic Control, Modelling and Simulation

Table 2
Real and coded values of input variables
Variable
Values
18.84
37.69
75.39
v [m/min]
-1
0
+1
vf
100
160
250
[mm/min]
-1
0
+1
1
2
4
aa [mm]
-1
0
+1
3
6
12
ar [mm]
-1
0
+1
Dependent variable studied was surface
roughness, evaluated by its Ra parameter (average
value) [m].
Measurements were done with digital Pocket
Surf (NAMICOM) apparatus. There was measured,
five times, an approximately, 50 mm long surface
region, the final value considered being the average
of each set of 5 measurements.
An image taken while measuring is shown in
figure 7 while, the resulting experiments values are
presented in Table 3.
Table 3
Experiments results
Exp.
Ra
Exp.
Ra
No.
No.
[m]
[m]
1
3,82
7
6,37
2
1,68
8
2,76
3
6,14
9
3,27
4
2,54
10
3,23
5
4,18
11
3,31
6
1,68
12
3,22

Fig. 8 REGS software experiment design and

data values setting

5 Regression models
Regression analysis was performed with REGS
software, a software designed for determining
coefficients of linear regression models [11] see
figure 8.
Results of regression analysis are presented in
Table 4 and, consequently, mathematical regression
model obtained is:

Ra = 2.397 v -0.623 v f 0.493 a a0.038 a r0.025

(3)

A glance on equation (3) points out the fact that

the strongest influence on surface roughness Ra
parameter values is that of cutting speed, v.
A more suggestive evidence of dependent
variable variation, on all of the studied independent
variable, can be performed by plotting graphs see
figure 9 (a. , b., c. and d.).
7

roughness, Ra [m]

vf = 100 [mm/min]
6

vf = 160 [mm/min]

vf = 250 [mm/min]

4
3
2
1

aa = 4 [mm]; ar = 12 [mm]

a.

18,8

26,6

37,7

53,3

75,4

cutting speed, v [m/min]

Fig. 9 Surface roughness variation graphs

Fig. 7 Measuring surface roughness

ISSN: 1790-5117

222

ISBN: 978-960-474-082-6

Proceedings of the 11th WSEAS International Conference on Automatic Control, Modelling and Simulation

Table 4
Regression Analysis Results
Orthogonal program
Model adequacy = 0.632
R* = 0.057< 1 ==> Adequate model
Coefficients significance
0 = 12094.19 > 1 ==> Significant variable
1 = 1080.36 > 1 ==> Significant variable
2 = 295.60 > 1 ==> Significant variable
3 = 3.99 > 1 ==> Significant variable
4 = 1.69 > 1 ==> Significant variable
B
b
b
b
b
b

coefficients
0 = 1.179
1 = -0.432
2 = 0.226
3 = 0.026
4 = 0.017

| Exp.
|no.

|
|
|
|
|
|
|
|
|
|
|
|

|
|
|
|
|
|
|
|
|
|
|
|

1
2
3
4
5
6
7
8
9
10
11
12
7

roughness, Ra [m]

A coefficients
a 0 = 0.874
a 1 = -0.623
a 2 = 0.493
a 3 = 0.038
a 4 = 0.025

Y VALUES
|Measured
| computed
3.820
1.680
6.140
2.540
4.180
1.680
6.370
2.760
3.270
3.230
3.310
3.220

|
|
|
|
|
|
|
|
|
|
|
|

3.824
1.669
6.214
2.534
4.170
1.700
6.329
2.763
3.250
3.250
3.250
3.250

|
ERRORS
| ABS.
| REL.

| CONFIDENCE INTERVALS
| Lower limit | Upper limit.

|
|
|
|
|
|
|
|
|
|
|
|

|
|
|
|
|
|
|
|
|
|
|
|

-0.00
0.01
-0.07
0.01
0.01
-0.02
0.04
-0.00
0.02
-0.02
0.06
-0.03

|
|
|
|
|
|
|
|
|
|
|
|

v = 18,84 [m/min]

-0.11
0.64
-1.21
0.24
0.24
-1.21
0.64
-0.11
0.60
-0.63
1.80
-0.95

|
|
|
|
|
|
|
|
|
|
|
|

4.201
1.834
6.827
2.784
4.581
1.868
6.954
3.035
3.368
3.368
3.368
3.368

v = 75,39 [m/min]

5
4
3
2
1

6
5
4
3
2
1

aa = 4 [mm]; ar = 12 [mm]
0

b.

3.481
1.519
5.656
2.306
3.795
1.548
5.761
2.515
3.137
3.137
3.137
3.137

v = 37,69 [m/min]

roughness, Ra [m]

R
R
R
R
R

v = 18,84 [m/min]

vf = 250 [mm/min]
ar = 12 [mm]

v = 37,69 [m/min]
v = 75,39 [m/min]

100,0

126,5

160,0

200,0

250,0

c.

cutting feed, vf [mm/min]

1,0

1,4

2,0

2,8

4,0

Axial cutting depth, aa [mm]

Fig. 9 Surface roughness variation graphs - continued

ISSN: 1790-5117

223

ISBN: 978-960-474-082-6

Proceedings of the 11th WSEAS International Conference on Automatic Control, Modelling and Simulation

Plotted graphs, based on the obtained regression

model, evidence the surface roughness variation on
each of the studied process parameters.
Further research should be developed, so as to get
other regression models of surface roughness and/or
milling force, cutting zone temperature, cutting tool
wear. All of them represent important and efficient
tools in studying polymeric composites materials
machinability, meaning knowing optimum process
parameters values, both as inputs, as well as outputs.

roughness, Ra [m]

6
5
4
3
2
1

v = 18,84 [m/min]

aa = 4 [mm]
vf = 250 [mm]

v = 37,69 [m/min]
v = 75,39 [m/min]

d.

3,0

3,9

5,0
7,7
12,0
Radial cutting depth, ar [mm]

Fig. 9 Surface roughness variation graphs - continued

6 Conclusion
Polymeric composites materials have known a
continuous extend lately, their high and special
characteristics pointing out their importance to
nowadays industry.
Reinforcing elements have the target of increasing
mechanical properties, very good results being
obtained when the reinforcing element is
represented by random oriented short glass fibers.
Several times, polymeric composites materials
parts cant be obtained to their final shape and
dimensions unless machining procedures are
performed. So, milling is often used and some
important parameters characterizing the process are
worth to be known.
Surface roughness of resulting machined surface
has been studied so that, the regression model
determined estimates the values of Ra roughness
parameter, related to the set values of main
cylindrical-face milling process parameters.
Simulation, with a specialized CNC machine
software, isyCAM has been done, in order to notice
eventual errors in cutting tool trajectory.
When modeling surface roughness, there has
been used a regression software, REGS, the results
pointing out the fact that all considered process
variables - cutting speed, v, cutting feed speed, vf ,
axial cutting depth, aa and radial cutting depth, ar
do significantly influence the Ra parameters values.
The highest influence is that of cutting speed, but
in a reverse way, meaning the higher v value, the
lower the Ra parameter value.
Other parameters decreasing influence has
resulted to be: cutting feed speed, axial cutting depth
and radial cutting depth.

ISSN: 1790-5117

224

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[1] Holcman Vladimr, Liedermann Karel, New
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[2] Hsu-Hwa Chang, Chih-Hsien Chen, Use of
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[3] Iliescu M., Spnu P., Costoiu M., Glass Fibres
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[4]
Iliescu M., Research on Quality and
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ISBN: 978-960-474-082-6