Surface topographic analysis of cutting inserts, Metal cutting, Cutting tool, Mountainsmap, surface roughness, ANOVA test

1. Master Thesis:
Surface topographical Analysis OF
Cutting inserts
2018-04-14
Master students in Mechanical Engineering
1
Final Presentation
Shobin & Zoelfi

2. AGENDA
 Cutting inserts and region of interest
 Aim of the study
 Theoretical framework
 Methodology
 Average and Standard deviation method
 Spearman’s correlation
 Error bar : Average and Standard deviation method
followed by Anova and T-test
 Results of work package 1 and work package 2
 Conclusion for work package 1 and work package 2

3. Cutting inserts and region of
interest
3 variants in WP1
1. MSG 157
2. MSG158
3. MSG 160
1. MSG 186
2. MSG187
3. MSG189
4. MSG190
5. MSG191
Edge Rounding +Pre
treatment
Post treatmentCoating
Treatment
5variantsinWP2

4. Cutting inserts and region of interest
Region of Interest
 Rake Face, it is defined as the whole upper side of the insert,
where the chips breaks
 Edge Rounding (ER), the radius of the cutting edge.
 All measurement had done on the rake face
 20 reading for each variant.
Rake face
Flank
face
Nose
Radius
Edge
Rounding

5. Aim of the study
 In Work Package one WP1 :
 Which are the Parameters are important when comparing different
variants ?
 Which Surface topography of the variants can correlate to the
manufacturing process?
 Is there any predominant direction of the topography?
 In Work Package Two WP2 :
 Which parameters are important to look at when comparing to each
other?
 If there is a connection can be found between the treatment prior to
coating and the outcome of the treatment after coating?
 If there is any different measurement approaches to measure the
surface roughness on variants in WP 1 and WP 2 ?

6. Theoretical framework
WP1Edge Rounding +Pre
treatment
• Surface texture measurement by
using interferometer and SEM.
• Software used after the reading
MountainsMap 7, Microsoft excel.
• 3D surface texture parameter ISO
25178-2
MSG157:Edge rounding is done through blasting.
The abrasive particles have a high kinetic energy
when they hit the surface of the inserts and therefore
some WC grains can break or crack.
MSG158: ER blasted; also blasted with a finer grit
size of media, the kinetic energy of the particles is
lower and thus the blasting should not fracture any
new grains of WC.
MSG 160:ER treated with blasting the same way as
MSG157 and MSG158 but before coating, it was
polished. The polishing is done through shooting out
rubber particles covered in a fine grit abrasive
material through a nozzle

7. Characterization

8. 1. Average and Standard deviation method
METHODS
1. Find the average and standard deviation
2. basis of the intervals and the mean
3. Then For each parameter, an interval for
good parts and for bad parts is calculated
with the coverage factor K, here we took
K=2
4. 𝐼′
𝑚𝑖𝑛 = 𝜇′
𝑖 − 𝑘𝜎′
𝑖 𝑎𝑛𝑑 𝐼′
𝑚𝑎𝑥 = 𝜇′
𝑖 +
𝑘𝜎′
𝑖
 Check threshold & disjunct function
 Select parameter have ´+´ve (disjunct)
significant factor
 Reject Parameters Have ´-´ Si factor
𝑆 =
𝑑(𝐼′ 𝑖, 𝐼′′ 𝑖)
1
2 (𝜇′ 𝑖 + 𝜇′′ 𝑖)
Parameters - According
to ISO 25178
Significant factor
between MSG157
and MSG158
Significant Factor
between MSG158
and MSG160
Significant Factor
between MSG157
and MSG160
Sa (Arithemetic Mean
Height)
Si Factor ´-´ve
Rejected
0,20 0,05
Smc (p = 10%)(Inverse
Areal Material Ratio
0,05 0,29 0,11
Sxp (p = 50%, q =
96.5%)(Extreme Peak
Height)
Si Factor ´-´ve
Rejected
0,13 0,04
Vv (p = 10%)(Void
Volume)
0,05 0,29 0,10
Vmc (p = 10%, q =
80%)(Core Material
Volume)
0,07 0,32 0,11
Vvc (p = 10%, q = 80%)
(Core Void Volume)
0,09 0,35 0,12

9. Spearman’s correlation coefficient is a statistical measure of the strength of a
monotonic relationship between paired data., is denoted by 𝑟𝑠 , monotonic is a
function between ordered sets that preserves or reverses the given order (in calclus
means function is strickly increases or strickly decreases either positive or negative
di= the difference between
the ranks of corresponding
values, n= number of value in each
data set
 Find the spearmen correlation
denoted by rs, (0≤rs ≤1.00).
• 020-39 Weak
• 0,4-0,69 Moderate
• 0,70-0,89 strong
• 0.9- 1, 0 very strong
Height Parameter
Sq
Ssk
Sku
Sp
Sv
Sz
Sa
Sq 100%
Ssk -54% 100%
Sku 44% -78% 100%
Sp 20% 25% 27% 100%
Sv 77% -84% 74% 7% 100%
Sz 71% -50% 73% 64% 81% 100%
Sa 83% -9% -9% 11% 39% 36% 100%
Selected
parameters
correlations
Smc Sq Vm Vv Vmc Sdq
Sxp 0,96
Sa 0,96
Vmp 1
Vmc 0,96
Vvc 0,99 0,99
Sdr 0,99
𝑟𝑠 = 1 −
6 𝑑𝑖
2
𝑁3 − 𝑑𝑖
2
𝑁
2. Spearman’s correlation

10. 1. Error bar : Average and Standard deviation method followed
by Anova and T-test
. Check the condition choosing the parameters:
 Error bar overlapping : Neglect
 All error bar not overlapping: Accept, means that experimental data
falling far Outside of Standard deviation are considered
. Error bar overlapping : Neglect
 All error bar not overlapping:
Accept, means that
experimental data falling far
Outside of Standard deviation
are considered

11. 1. Error bar : Average and Standard deviation method
followed by Anova and T-test
Analysis of variance
 Find the sum of parameters for each variant
 Find the mean(average) for each variant
 Find the difference between the observation and the mean (X-mean)
 Find the variance (X-mean)2 Sum of the square
 Find the total sum of the observation of the variants
 Find the total sum of the square between group and the sum within the group
 Find the degree of freedom between the group as well as with the group
 Divide the sum of squares between groups by the degree of freedom
between groups MSw, divide the sum of squares within groups by degree of
freedom within groups MSB
 Find F statistic ratio equal = MSw/ MSB
 F > F Critical and P value less than 0.05 (p < 0.05) with (95% confidence), and
degree of freedom between group <F < degree of freedom within group,
means variants interval are disjunct for particular parameter (TRUE).

12. TRUE P(T<=t)t
wo
tail<(0,05
)
Parameter is disjunct for variants with
95% confident interval
FALSE P(T<=t)t
wo
tail>(0,05
)
Parameter is non-disjunct for variants
with 95% confident interval
PARAMETERS
(ISO25178,WP2)
NumberTRUE
S (Row)>6
Accept/
Reject
Sa(Arithemefic Mean
Height)
7 Accept
Smc (InverseAreal Material
Ratio)
8 Accept
Vv(Void Volume) 8 Accept
Vmc (Core Material
Volume)
8 Accept
Vvc(Core Void Volume) 8 Accept
Comparisn Between
Different
Variants(WP2)
Number of
TRUES(Coulu
mn) >15
SignificantI
Not
Significant
Comparison
between MSG186&
189
18 Significant
Comparison
between MSG189&
190
22 Significant
Comparison
between MSG189&
191
22 Significant
PARAMETERS
MSG186and187
MSG186and189
MSG186and190
MSG186and191
MSG187and189
MSG187and190
MSG187and191
MSG189and190
MSG189and191
MSG190and191
Sq F T F F F F F T T F
Ssk T F T F F T T T T F
Sku F F T T F T T T T F
Sp F T F F F F F T T F
Sv F T F F T F F T T F
Sz F T F F T F F T T F
Sa F T T T F T T T T F
Smr T T F F T T F T T F
Smc T T T T F T T T T F
Sxp F T F T F F F T T F
Sal T F T F T T T F F F
Str F T T F F F F T T F
Std F F F F F F F F F F
Sdq F T F F T F F T T F
Sdr F T F F T F F T T F
Vm F T F F F F F T T F
Vv T T T T F T T T T F
Vmp F T F F F F F T T F
Vmc T T T T F T T T T F
Vvc T T T T F T T T T F
Vvv F T F F T F F T T F
Spd F F T T F T T T T F
Spc F T T T T F F T T F
F: FALSE T: TRUE
• The comparison between the MSG186 and
MSG189, MSG189 and MSG190 , MSG189
and MSG191 are the highly significant
• The comparison between the MSG186 and
MSG189, 18 Trues in the column
• MSG189 and MSG190 , MSG189 and
MSG191 are the highly significant, 22
TRUES in the column

13. 2. Average and Standard deviation method
METHODS
1. Find the average and standard deviation
2. basis of the intervals and the mean
3. Then For each parameter, an interval for
good parts and for bad parts is calculated
with the coverage factor K, here we took
K=2
4. 𝐼′
𝑚𝑖𝑛 = 𝜇′
𝑖 − 𝑘𝜎′
𝑖 𝑎𝑛𝑑 𝐼′
𝑚𝑎𝑥 = 𝜇′
𝑖 +
𝑘𝜎′
𝑖
 Check threshold & disjunct function
 Select parameter have ´+´ve (disjunct)
significant factor
 Reject Parameters Have ´-´ Si factor
𝑆 =
𝑑(𝐼′ 𝑖, 𝐼′′ 𝑖)
1
2 (𝜇′ 𝑖 + 𝜇′′ 𝑖)
Parameters - According
to ISO 25178
Significant factor
between MSG157
and MSG158
Significant Factor
between MSG158
and MSG160
Significant Factor
between MSG157
and MSG160
Sa (Arithemetic Mean
Height)
Si Factor ´-´ve
Rejected
0,20 0,05
Smc (p = 10%)(Inverse
Areal Material Ratio
0,05 0,29 0,11
Sxp (p = 50%, q =
96.5%)(Extreme Peak
Height)
Si Factor ´-´ve
Rejected
0,13 0,04
Vv (p = 10%)(Void
Volume)
0,05 0,29 0,10
Vmc (p = 10%, q =
80%)(Core Material
Volume)
0,07 0,32 0,11
Vvc (p = 10%, q = 80%)
(Core Void Volume)
0,09 0,35 0,12

14. Spearman’s correlation coefficient is a statistical measure of the strength of a
monotonic relationship between paired data., is denoted by 𝑟𝑠 , monotonic is a
function between ordered sets that preserves or reverses the given order (in calculus
means function is strickly increases or strickly decreases either positive or negative
di= the difference between
the ranks of corresponding
values, n= number of value in each
data set
 Find the spearmen correlation
denoted by rs, (0≤rs ≤1.00).
• 020-39 Weak
• 0,4-0,69 Moderate
• 0,70-0,89 strong
• 0.9- 1, 0 very strong
Height Parameter
Sq
Ssk
Sku
Sp
Sv
Sz
Sa
Sq 100%
Ssk -54% 100%
Sku 44% -78% 100%
Sp 20% 25% 27% 100%
Sv 77% -84% 74% 7% 100%
Sz 71% -50% 73% 64% 81% 100%
Sa 83% -9% -9% 11% 39% 36% 100%
Selected
parameters
correlations
Smc Sq Vm Vv Vmc Sdq
Sxp 0,96
Sa 0,96
Vmp 1
Vmc 0,96
Vvc 0,99 0,99
Sdr 0,99
𝑟𝑠 = 1 −
6 𝑑𝑖
2
𝑁3 − 𝑑𝑖
2
𝑁
3. Spearman’s correlation

15. Results of work package 1
• The colour code of
the table is based on
the visual
estimations.
• Comparison between
different variants
with selected
parameters only used
for compare this
particular study.
B: blasting,
FGB: fine grain blasting,
P: polishing
SURFACE TEXTURE
ANALYSIS
Comparison only for WP 1
variants
Description for highest
values
Parameter Selected IS025178-2
Sa
Arithemeti
c Mean
Height
Sxp
(p = 50%),
(q=97.5%)
Smc
(P=10%)
Vv
(p =10%)
Vmc
(p=10%)
(q=80%)
Vvc
(p=10%,
q= 80%)
Units
µm µm µm µm³/µm² µm³/µm² µm³/µm²
Smooth <0,20 <0,6 <0,30 < 0,30 <0,20 <0,30
Medium 0,20-0,30 0,6-0,8 0,30-0,40 0,30-0,50
0,20-
0,30
0,30-
0,40
Rough >0,30 >0.8 >0.50 >0,50 >0,3 >0,40
MSG157
( B)
Higher bearing
of the material
from peak,
More Texture.
0,25 0,71 0,39 0,40 0,27 0,35
MSG158
(B-FGB)
Higher overall
texture, Higher
Bearing area.
Higher amount
fluid retention.
0,33 0,88 0,52 0,54 0,34 0,47
MSG160
(B.P )
Wide space
texture,
Comparatively
smooth surface
0,19 0,52 0,29 0,30 0,19 0,26

16. Results of work package 1
Sa=0,31um
Sa=0,34um
Sa=0,23um
MSG157
MSG160
MSG158
MSG157
MSG158
MSG160

17. • MSG157 surface characteristics, Str=0,7 Texture as suggesting highly isotropic texture,
without any lay. Uniform surfaces texture in all direction
• MSG158 Shows more texture, Str=0,4 Surface has a medium anisotropic texture
indicates or the presence of a dominating pattern in certain directions.
• MSG160 shows smoother Surface, anisotropic Str=0,3 Surface shows a
directionality.
MSG158
0.200
Parameters Value Unit
Isotropy 90.3 %
Periodicity ***** %
Period ***** µm
Directionof period ***** °
Results of work package 1
MSG160
0.200
Parameters Value Unit
Isotropy 59.1 %
Periodicity ***** %
Period ***** µm
Directionof period ***** °
0.200
Parameters Value Unit
Isotropy 84.5 %
Periodicity ***** %
Period ***** µm
Directionof period ***** °
MSG157
Str=0,7 Str=0,4 Str=0,3

18. Results of work package 2
PARAMETERS Selected From ISO 25718-2
Sa Smc (p = 10%)
Vv (p =
10%)
Vmc (p =
10%, q =
80%)
Vvc (p =
10%, q =
80%)
SURFACE TEXTURE ANALYSIS
(Comparison only for WP2 variants &
Description for highest values)
Units µm µm µm³/µm² µm³/µm² µm³/µm²
Smooth <0,2 <0,25 0,25 <0,20 <0,20
Medium 0,2-0,35 0,25-0,45 0,25 -0,50 0,2-0,30 0,20-0,35
Rough >0,35 >0,45 >0,50 >0,30 >0,35
Variant Surface
MG186 B-0-B
High bearing of materials
from peak
0,20 0,30 0,32 0,19 0,26
MSG187 B-FGB-B
High fluid retention and
scrap entrapment, Much
material beard away during
process, high bearing area
0,32 0,46 0,47 0,28 0,39
MSG189 B-P-B
High overall texture, high
bearing of material from
peaks, more fluid retention,
more wetted surface
0,37 0,49 0,52 0,26 0,40
MSG190 B-P-B, P
Surface in good condition,
smooth flat surfaces 0,17 0,24 0,24 0,15 0,19
MSG191 B-0-B,P
Surface in good condition,
smooth and flat surfaces 0,19 0,22 0,21 0,15 0,17
B: Blasting; FGB: Fine Grain Blasting; P: Polishing

19. 0 20 40 60 80 100 %
µm
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Vmp
Vmc Vvc
Vvv
10.0 %
80.0 %
0 20 40 60 80 100 %
µm
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Vmp
Vmc Vvc
Vvv
10.0 %
80.0 %
MSG186
0 20 40 60 80 100 %
µm
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
Vmp
Vmc Vvc
Vvv
10.0 %
80.0 %
µm
7.706
0
1
2
3
4
5
6
7
Roughness (Gaussian filter, 80 µm)
MSCG187
MSCG187
µm
3.865
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
Roughness (Gaussian filter, 80 µm)
MSG186
MSG186
µm
11.736
0
1
2
3
4
5
6
7
8
9
10
11
Roughness (Gaussian filter, 80 µm)
MSCG189
Sa=0,20um
Sa=0,32um
Sa=0,37um

20. µm
5.378
0
1
2
3
4
5
Roughness (Gaussian filter, 80 µm)
0 20 40 60 80 100 %
µm
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Vmp
Vmc Vvc
Vvv
10.0 %
80.0 %MSG190
MSG190
0 20 40 60 80 100 %
µm
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
Vmp
Vmc Vvc
Vvv
10.0 %
80.0 %
MSG191
MSG191
µm
5.005
0
1
2
3
4
Roughness (Gaussian filter, 80 µm)
MSG191
Sa=0,17um
Sa=0,19um

21. Conclusion of work package 1
• The parameters which are important to look at when comparing the different variants to
each other are: arithmetic mean height(Sa), extreme peak height(Smc), void
volume(Vv), Core material volume(Vmc), Core void volume(Vvc) and Area
height difference(Sxp).
 Which parameters are important for comparing the different variants to each
other?
Variants Manufacturing Process Comments are based on the analysis
from the parameters
MSG157 Blasting Higher bearing of the material from peak,
More Texture.
MSG158 Blasting followed by fine grain
blasting
Higher overall texture, Higher Bearing
area. Higher amount fluid retention.
MSG160 Blasting followed by polishing Wide space texture, Comparatively
smooth
 How well does the study of surface topography of variants correlate to the
manufacturing process?
 If there are a predominant direction of the topography? Yes
• MSG 157 shows larger ratio values i.e. Str> 0.5, indicate isotropy or uniform surface texture in all
directions.
• MSG 158 Indicates anisotropy or the presence of a dominating pattern in certain directions
• MSG 160 Str= 0,3 value shows small value; indicate anisotropy or the presence of a dominating
pattern in certain directions. It shows certain directionality.

22.  If there is a connection found between the treatment prior to
coating and the outcome of the treatment after coating? Yes
 Which are the parameters are important to look at when comparing to
each other?
The parameters which are important to look at when comparing the different variants
to each other are: arithmetic mean height (Sa), extreme peak height (Smc), void
volume (Vv), Core material volume (Vmc) and Core void volume (Vvc).
Variants
Manufacturing Process
(Pretreatment-ER Treatment-
Post treatment)
Comments are based on the analysis from the
parameters
MSG 186 Blasting -0-Blasting High bearing of materials from the peak
MSG 187 Blasting- Fine Grain Blasting-
Blasting
High fluid retention and scrap entrapment. Much
material beard away during process, high
bearing area
MSG 189 Blasting -Polishing-Blasting
High overall texture, high bearing of material
from peaks, more fluid retention, more wetted
surface
MSG 190
Blasting -Polishing- Blasting,
Polishing
Surface in good condition, smooth and flat
surfaces
MSG 191
Blasting -0-Blasting, Polishing Surface in good condition, smooth and flat
surfaces
Conclusion of work package 2

23.  Is there any different measurement approach needed to evaluate the surface
roughness on variants in Work Package 2 compared to Work Package 1? Yes
Interferometer Reading
Variants
>3
Select Parameter
NEBNO=V
𝑺 𝒊 <
𝟎. 𝟎𝟓
𝑽
Number of
Trues > V+1
Reject Parameter
Yes
Work Package 2
Yes
Work Package1
Yes
No
NO NO
Yes
NEBNO=V
Yes
Yes
Average and SD
Custom Error Bar
Nod
MountainsMap
Excel/SPSS

24. PHASE 1 PHASE 2 PHASE 3
ccMSG 157
Blasting,
Sa=0,3um
MSG 158
Blasting-Fine Grain
Blasting
Sa=0,3um
MSG 160
Blasting-Polishing
Sa=0,2um
MSG 186
Blasting-0-Blasting
Sa=0,2um
MSG 187
Blasting-Fine Grain
Blasting-Blasting
Sa=0,3um
MSG 189
Blasting-Polishing-
Blasting
Sa=0,4um
MSG 190
Blasting-Polishing-
Blasting, Polishing
Sa=0,2um
MSG 191
Blasting-0-Blasting,
Polishing
Sa=0,2um
 Comparison of different variants for work package1 and work package 2
Work Package 1 Work Package 2