A new algorithm for developing a reference-based model for predicting surface roughness in finish machining of steels

It is well known that the surface roughness predicted from a theoretical model often shows a considerable difference from that obtained from the actual experimental results. However, it is extremely costly and time consuming to develop a general empirical equation, in particular with the great varieties of tool chip breakers and work materials, which have shown significant effects on surface finish quality. This paper presents a new algorithm to establish a reference tool based model for predicting surface roughness through the correlation analysis and regression method. The advantage of it is that once a reference model has been identified, the effects of new tool chip breakers and work materials can be quantitatively included by only conducting a set of representative experiments. The algorithm, comparing with the traditional method, takes much less experimental work while showing a reasonable accuracy in predicting the surface roughness in finish machining. The algorithm presented in this paper provide...