Effects of grain angle on the amplitudes of acoustic emission and surface roughness in wood machining

The orientation of wood fibers and the resulting surface roughness of radiata pine are studied during a peripheral milling with acoustic emission control. Studies were undertaken in machining process for radiata pine, where a surface quality problem appears when cutting is not well controlled. It is known that acoustic emission signals are a good monitoring element of the surface roughness with different cutting conditions. Previous studies have shown that changing cutting conditions affects acoustic emission signals; these variations are related to surface roughness and chip formation. The purpose of this study is to evaluate and quantify the surface quality and the consumption of cutting energy in radiata pine with differing grain angles, and to determine the relationships of grain angle with acoustic emission signals in order to better optimize cutting conditions.     

Prediction of the surface roughness of wood for machining

The surface quality of solid wood is very important for its effective response in manufacturing processes. The effects of feed rate, cutting depth and rake angle on surface roughness and power consumption were investigated and modeled. Neuro-fuzzy methodology was applied and shown that it could be useful, reliable and an effective tool for modeling the surface roughness of wood. Thus, the results of the present research can be successfully applied in the wood industry to reduce time, energy and high experimental costs.     

Effects of commercial thinning,log position in the stem,and cutting width on the surface quality of cants produced by a chipper-canter

Fifteen stems of jack pine (Pinus banksiana Lamb.) of 3 commercial thinned plots (control, moderate, and intensive thinning) and 15 stems of black spruce (Picea mariana (Mill.) B.S.P), both coming from the Abitibi-Témiscamingue region – Canada, were cross-cut into three 2.4?m length sections: bottom, middle, and top logs. Logs were processed with a chipper-canter at three cutting widths (12.7, 19.1, and 25.4?mm), producing chips and a three-faced cant. The middle section of the cant was used to evaluate surface quality across the grain on each face. Roughness and waviness parameters and depth of torn grain were recorded. Knot characteristics were assessed in the three cant faces. Poorer surface quality was found in the lower part compared to the upper part of the cant for both species. At larger cutting widths, jack pine logs coming from a natural stand showed lower surface quality compared to logs from thinned stands. Black spruce waviness increased with the cutting width and stem height. These results were attributed to the increase of forces and vibration when cutting at larger cutting widths, which was worsened by the presence of bigger, more numerous knots at the control plot and in the top logs. Black spruce had deeper torn grain compared to jack pine. Their differences in knot characteristics resulted in a maximum torn grain depth favored by the presence of more knots rather than by bigger knot size. Other knot characteristics, such as the position of the knots in the cant face, the insertion angle of the branch and the distribution of the knots around the log, should be studied to better understand the relationship between torn grain formation and knottiness.     

The effects of wood-fiber directions on acoustic emission in routing

The purpose of this study was to investigate the causes of changes in acoustic emission (AE) signals corresponding to changes in grain orientation in routing. Both the AE signals and the state of cutting process were recorded on high-speed video cameras in an attempt to clarify the relationships between them. Based on the results, it appeared that generated AE was closely related to the state of cutting, as well as the surface finish. The greater the AE, the more severe the cutting performance for inclination angles. The greatest AE was generated when machining failures – fuzzy grains – were produced. Concerning the annual ring angle, the AE count rate, lowest at 0 degrees, slightly increased until 75 degrees, and then rapidly reached its maximum at 90 degrees. Changes in the slope angle had also an effect on the AE signal. The AE count rate, highest at the 0 degrees, gradually decreased until 75–105 degrees, and then increased to reach its maximum at 180 degrees. Moreover, there were correlations between the AE count rate and surface roughness. Therefore, acoustic emission has shown promise for the monitoring of the surface roughness including various cutting conditions. Received 23 September 1998     

木工圆锯片锯齿侧刃参数对锯切表面粗糙度的影响

【目的】分析锯齿侧刃参数对锯切表面粗糙度的影响,通过优化锯齿侧刃参数,解决圆锯锯切时进给速度提高与表面粗糙度增大之间的矛盾,为新型木工圆锯片设计提供参考和指导。【方法】提出微量零径向侧后角锯齿的概念,使用9种不同锯齿侧刃参数的圆锯片,以水曲柳和高密度纤维板为对象进行锯切试验,研究不同进给速度下径向侧后角和零径向侧后角段对锯切表面粗糙度的影响。【结果】随着进给速度增加,锯切表面粗糙度增大,径向侧后角减小,锯切表面粗糙度降低,无零径向侧后角段锯齿锯切形成的表面粗糙度均高于具有零径向侧后角段锯齿,特别是当零径向侧后角段由0 mm增加到0.5 mm时,锯切表面粗糙度下降最为明显。当零径向侧后角段大于0.5 mm时,侧刃的零径向侧后角段具有"以锯代刨"的作用,与零径向侧后角锯齿相比同样可起到改善锯切表面质量的作用。【结论】锯切表面粗糙度一定程度上取决于锯痕深度。在实际锯切过程中,仅有长度近似等于每齿进给量的锯齿侧刃部分参与切削,占侧刃总长度的很小一部分,微量零径向侧后角锯齿中零径向侧后角段长度比每齿进给量略大且越接近每齿进给量越理想。具有微量零径向侧后角段锯齿的圆锯片与零径向侧后角锯齿相比,同样可起到改善锯切表面质量的作用;在保持其他切削参数不变的情况下,微量零径向侧后角段锯齿还可以减小锯齿侧刃与锯路壁之间的摩擦。     

木材纵横向切削过程中的声发射特性

研究了木材纵横向切削过程中的声发射特性。结果表明,切削方向与纤维方向之间的夹角,对切削过程中的声发射活动影响显著;当夹角为0°时声发射最强,90°时声发射最小;声发射强度随木材表面粗糙度的减小而逐渐增大。通过获得的试验数据,可进一步完善切削理论,指导木制品生产,监控产品质量。     

Effects of helical angle of router bit on acoustic emission

The purpose of this study was to investigate the effects of changes in the helical angle of the router bit on the acoustic emission (AE) signal for various workpiece grain angles. The helical angle varied from 0° to 50° at 10° increments. The workpiece grains were oriented from 0 degrees (cutting parallel to the grain), through 90° (cutting end of the grain), to 165° at 15° increments. The AE signals and machined surface roughness were measured in an attempt to clarify the relations between them. The results were summarized as follows: (1) The AE signals were lowest in the with the grain cutting zones and slightly increased in the against the grain cutting zones; they rapidly reached the highest values at the 135°–165° grain angles. The greater the helical angle of the router bit, the smaller were the AE count rates for each grain angle investigated. There was no significant change in AE generation for helical angles of 0° and 10°. Moreover, the greater the feed rate, the greater was the AE count rate for every cutting condition investigated. (2) The surface roughness, similar to the AE count rate, had the lowest values in the with the grain cutting zones, slightly increased until the 120° grain angle, and then rapidly become extremely rough, reaching a maximum at the grain angles of 135°–150°. There was no remarkable change in the machined surface roughness while routing with the grain using the router bit of greater helical angle. However, when routing against the grain, the greater the helical angle the smoother was the machined surface. (3) There were correlations between the AE count rate and the machined surface roughness for each helical angle investigated. Therefore, acoustic emission has shown promise for monitoring and controlling the routing operation, including various grain angles and helical angles of the router bit.     

沙柳材端向切削特性的研究

为了明确影响灌木材端向切削力的主要因素,改进削片机性能,提高灌木材削片质量,笔者研究了不同刀具前角、切削厚度和不同含水率对沙柳(Salix psammophila)材端向切削力的影响。结果表明刀具前角对法向力的影响较小,对主切削力影响较大;切削厚度对主切削力的影响较为明显,随切削厚度的增加,主切削力明显增加;沙柳材含水率15％以下主切削力随含水率增加略有增大,之后逐渐减小,其中含水率在30％-70％之间时,切削力变化不大。     

Wear and blunting of the tool corner in cutting a wood-based material

Summary A study was made of relationships between wear (loss of metal) and blunting (reduced performance) of the corner of a steel cutting tool turning a work-piece of hard fibreboard. Rake angle, clearance angle and surface preparation (grinding, polishing) were varied and measurements made were the three cutting force components and various wear parameters. It was confirmed that retraction of the edge from its initial position is not a satisfactory index of blunting and that the shape parameter corresponding to compression of the cut surface (negative clearance) was most influential. Also, for the particular tool and work-piece materials used and in the practical range of bluntness, the ratio of negative clearance to the width of the back wear land, as measured parallel to the cutting plane, was roughly constant. It is evident that development of a hard, very thin layer on the back face would minimize negative clearance and extend sharpening life. In the practical range for cutting wood and wood-based materials, clearance angle had a relatively small effect on the rate at which negative clearance and cutting forces increased, and rake angle had negligible effects. It is concluded that these angles should not be increased without taking into account factors other than blunting. Polishing considerably decreased blunting rate, especially of the tool corner, which is especially important in sawing. The expense of polishing may be justified in some exacting operations.     

切削参数对木材切削力的影响

为了提供圆锯片合理设计与使用的依据,对水曲柳、杉木和樟子松3种木材进行闭式切削试验,研究锯齿前角、切削厚度、切削速度等参数对切削力的影响规律。结果表明:主切削力和法向切削力均随锯齿前角的增大而减小,随切削厚度的增加而增大,而受切削速度的影响较小。根据试验结果,提出不同密度木材切削参数设置的建议。     

Analysis of sanding parameters on surface properties and coating performance of red oak wood

Sanding is the most common machining process used to prepare wood surfaces prior to coating. Hence, to improve surface quality and coating performance during this process, an optimal set of machining parameters should be established according to wood species and its final use. The effects of grit size and feed speed on surface properties and coating performance of red oak wood were studied. Surface quality was assessed by surface roughness, scanning electron micrographs, and wetting analyses. Coating performance was evaluated using pull-off adhesion tests on coated surfaces before and after an accelerated weathering. The results showed that smoother surfaces are obtained as the grit size number of the abrasive increased. On the other hand, minor differences were observed on cell damages and surface roughness as feed speed changed. Also, there was little difference among treatments concerning wetting behavior and surface energy. Pull-off strength was more affected by changes in grit size than feed speed. A P100-grit size program with a feed speed of 7 m/min resulted in a suitable roughness which provided good adhesion and high pull-off strength after aging test.     

锯片锯料角对锯切表面粗糙度影响机理分析

分析了锯料角影响锯切表面粗糙度的机理，阐述了锯料角与锯料量对锯切表面粗糙度的影响。分析结果表明，只要锯料角不变化，则锯料量的变化对锯切表面粗糙度不起任何作用。锯料角影响锯切表面粗糙度的机理为开发新型锯片、提高锯切表面的质量和锯切效率提供依据。     

Towards a model predicting cutting forces and surface quality in routing layered boards

The general aim of work reported here was to assist designers and operators of routers and similar tools for cutting wood-composite boards, by providing a model predicting cutting force components from readily available material properties. This initial study explored, for edge cutting, the variation within a single medium density fibre board across the thickness and in various cutting directions in the plane of the board. Material properties of interest were specific gravity and friction coefficient. In slow linear cutting on a modified milling machine, carbide router inserts cut the edges of layers cut from a medium density fibre board. Specific gravity and coefficient of sliding friction were measured for each layer. Cuts were also made on full-thickness edges in various directions in the plane of the board. Chip thickness was varied from 0.025 to 0.8 mm. Parallel and normal force data and digital video images of chip formation were stored for analysis. Specific gravity increased as the fourth power of the distance from the central plane to the surface. Friction coefficient values, estimated both from cutting forces and from rubbing forces during return, varied about a value of 0.23, with no significant difference between layers. The values for cutting force per mm width of cut increased progressively from the central plane to the surface, in a logarithmic relation with specific gravity. The cutting forces did not vary with cutting direction in the plane of the board. For a sharp edge with 32° rake angle cutting at chip thickness values above 0.1 mm, the normal force component was negative, indicating reduced feed force and improved surface quality. With dulling, the threshold value of chip thickness for this increased. It is concluded that elaboration of this approach would generate relationships suitable for incorporating in a useful general model. However, it may be found that weight per unit area of board will suffice as a proxy for cutting resistance in modelling the cutting of full-thickness edges. Received 10 June 1999     

On-line determination of the grain angle using ellipse analysis of the laser light scattering pattern image

Under fixed cutting conditions, the surface finish roughness is correlated to the grain angle. However, the means of determining the grain angle automatically and accurately is still a challenge for on-line control of the router. It is therefore necessary to develop a new technology to determine the grain angle accurately and automatically. In this research, a laser light scattering pattern was used to accurately determine the grain angle. The light scattering pattern image was a quasi-ellipse caused by the grain direction and tracheid effect. A new modified Hough transform ellipse analysis technology was adopted to determine the ellipse parameters that could be used to determine the grain angle. The results indicated that the measured grain angle using the method proposed here was accurate and effective. The measured grain angle coincided with the real grain angle. There was an insignificant difference between the measured grain angle of Japanese beech (Fagus crenata blume) and that of sugi (Cryptomeria japonica D.Don) under two machining conditions that gave planed or sawn finishes. However, the accuracy of the measured grain angle of sugi was better than that of Japanese beech for the planed finish, the accuracy of the measured grain angle of Japanese beech was better than that of sugi for the sawn finish, and the accuracy of the measured grain angle for planed samples was better than that for sawn samples of both sugi and Japanese beech.     

铣削参数对毛竹表面粗糙度影响的研究

通过对毛竹(Phyllostachys pubescens)的铣削实验,研究刀具前角、铣削深度、每齿进给量对其径向铣削表面粗糙度的影响.结果表明:随刀具前角的增大,铣削表面粗糙度各项指标中,轮廓高度方向指标Ra、Rz、厨均有所增大,但增幅不明显;而轮廓峰谷间距有所下降.铣削深度对表面粗糙度各参数并无明显影响.每齿进给量Uz对铣削表面粗糙度高度方向指标影响不明显,Sm值与Uz呈良好的正相关关系.     

Residual strain analysis with digital image correlation method for subsurface damage evaluation of hinoki (<Emphasis Type="Italic">Chamaecyparis obtusa</Emphasis>) finished by slow-speed orthogonal cutting

A digital image correlation (DIC) method was applied to measure strain which arose and remained beneath the finished surface in slow-speed orthogonal cutting of hinoki (Chamaecyparis obtusa), to evaluate the damage in the subsurface cell layers. While the quarter-sawn surface was cut parallel to the grain, the side surface, flat-sawn surface, was captured by a high-speed camera. The images were analyzed to calculate strain in a region of 0.67 × 0.22 mm allocated beneath the finished surface. Almost no strain normal to the cutting direction was detected for the depth of cut and cutting angles, 0.05 mm and smaller than 60°, respectively. For the depths of cut and cutting angles, larger than 0.1 mm and smaller than 60°, respectively, the fore-split induced tensile strain normal to the cutting direction, although it hardly remained after the cutting. The compression strain normal to the cutting direction clearly remained for the cutting angles larger than 70°, regardless of the depths of cut employed in this study. The subsurface damage assumed from the residual strain distribution corresponded to the appearance of the subsurface layer in the X-ray computed tomography (CT) images. It was also revealed, and the DIC program could not always measure excessively large strain correctly.     

The influences of circular saws with sawteeth of mic-zero-degree radial clearance angles on surface roughness in wood rip sawing

Key message

The sawtooth parameters of the side edges likely affect surface roughness to a large extent in wood sawing. Our results point out the need to optimize the parameters of the side edges in order to maximize wood surface quality.

Context

Improving surface roughness of wood in rip sawing by optimizing the sawtooth parameters is a significant topic of focus in the research of wood processing. However, existing research focuses mainly on the optimization of the sawtooth parameters of the major cutting edges without taking into account the influences of length and angle of the side edges on surface roughness. Thus, adaptive parameters for the side edges should be proposed.

Aims

This study analyzes how the different parameters of side edges influence surface roughness when circular saws are used, and aims to resolve disparities between high feed speeds and better surface roughness.

Methods

In particular, this article presents the use of a sawtooth with a mic-zero-degree radial clearance angle. Northeast China ash (Fraxinus spp.) serves as the material for conducting this rip-sawing experiment. Nine types of sawtooth geometries at different feed speeds are used to study the influences of both the different radial clearance angles and the straight length of the zero-degree radial clearance angle on surface roughness (Ra).

Results

Surface roughness increases with the increase in feed speed, and the smaller the radial clearance angle of the sawteeth, the smaller the surface roughness. When the sawteeth have a mic-zero-degree radial clearance angle, the sawing surface roughness is lower than that of the value of sawteeth with radial clearance angles, especially when the straight length of the zero-degree radial clearance increases from 0 to 0.5 mm, in which case the decrease is most obvious.

Conclusion

Surface roughness depends, to a certain extent, on the depth of the saw notch. A small part of the side edge that forms the sawing surface participates in the actual cutting, and the length of this section is approximately equal to the feed per tooth. Sawteeth with mic-zero-degree radial clearance angles can improve the surface quality of sawing. Also, if the other cutting factors remain unchanged, surface roughness can be improved and friction can be reduced between the side edges and the wood by increasing the feed speed.

     

STUDY ON MEASUREMENT OF WOOD SURFACEROUGHNESS BY COMPUTER VISION

The working processes,machining devices and tools,cutting amount,consumptionof materials,productivity and quality of products are directly affected wood surface roughness.This paper gives an extensive review of methods used previously to measure wood surfaceroughness,and concludes that computer vision is the most suitable.The preliminarystudy shows that computer vinon method has the advantages of a noncontact,three--dimensionalmeasurement,high speed and well correlates with stylus tracing method.The method can be usedin classification and in-time measurement of wood surface roughness after being improved.     

自制测力仪用于木材三向切削力的测定

评定木材切削刀具的切削性能及切削表面的加工质量时，均需测定木材切削时的三向切削力：主切削力、进给力及侧向力，因此设计一台合适的三向测力仪成为关键。本文以单一八角环为基础，引申出单向延伸式八角环、组合式八角环及双向延伸式八角环测力仪，并逐一分析其结构特点及应用于木材三向切削力测定的可行性。最终确定双向延伸式四耳环八角环性能最优，并对其进行设计、制选、标定及切削试验。试验结果表明该型完全符合木材三向切削力测定的要求。     

Effects of abrasive mineral, grit size and feed speed on the quality of sanded surfaces of sugar maple wood

Sanding is a common practice required in order to prepare wood surfaces for coating. Little literature is available regarding the effect of sanding parameters on the quality of surfaces. Sugar maple wood surfaces were evaluated in samples that had been sanded using two types of abrasive minerals, three grit sizes and four feed speeds. Roughness, wetting properties and cell damage were used to assess surface quality. Both abrasives decreased roughness and cell damage from 100- to 120-grit sanding stage. Addition of a 150-grit stage did not further reduce the roughness, whereas the cell damage continued to decrease. Increasing feed speed led to rougher surfaces due to higher fibrillation. Surfaces produced by silicon carbide were smoother and less damaged than those obtained with aluminum oxide. However, the surfaces sanded with aluminum oxide were more wettable and showed no significant difference in wetting time as a function of grit size. For these surfaces, the wetting time was reduced as feed speed increased.An erratum to this article is available at .An erratum to this article can be found at