Application of hybrid incremental modeling for predicting surface roughness in micromachining processes

This paper presents the application of a hybrid incremental modeling strategy (HIM) for real-time estimation of surface roughness in micromachining processes. This strategy essentially consists of two steps. First, a representative hybrid incremental model of micromachining process is obtained. The final result of this model describes output as a function of two inputs (feed per tooth quadratic and vibration mean quadratic (rms) in the Z axis) and output (surface roughness R_a). Second, the hybrid incremental model is evaluated in real time for predicting the surface roughness. The model is experimentally tested by embedding the computational procedure in a real-time monitoring system of surface roughness. The prototype evaluation shows a success rate in the estimate of surface roughness about 80%. These results are the basement for developing a new generation of embedded systems for monitoring surface roughness of micro components in real time and the further exploitation of the monitoring system at industrial level.