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 Ra). 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.