Skip to main content
SpringerLink
Log in

Mathematical modeling of surface roughness in polystyrene foam machining

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

In the present era, polystyrene foam is widely used in foundries for pattern making. Industries extensively use the steam molding routes for polystyrene foam pattern making. However, the molding method cannot produce complex geometries. Industries are using the machining route for pattern making to overcome these limitations. There is limited research carried out on expanded polystyrene foam machining. Patterns need smooth surfaces with minimum surface roughness to make good quality castings. Therefore, there is a need to predict the surface roughness and its affecting parameters for polystyrene foam machining. The present article discusses a new theory for foam machining. The preliminary experiments identified two cutting mechanisms, mechanism I (through bead cutting) and mechanism II (bead removal). A novel mathematical model for the surface roughness has been developed and experimentally validated. A close correlation between the predicted and experimental values of average surface roughness (Ra) is observed with an average error of 19.70%. The correlation analysis shows a 93.07% correlation between the predicted and experimental values. The proposed mathematical model has been segregated into two parts because of through bead cutting and bead removal. Observation shows, the model part due to bead removal contributes significantly more (approximately 90% for all experiments) to the surface roughness. Therefore, surface roughness can be improved by minimizing or avoiding bead removal.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10

Similar content being viewed by others

Abbreviations

R a :

Average surface roughness

A d :

Bead dislocation/removal area

A b :

Distorted bead area

d :

EPS foam bead diameter(mm)

a :

Cord diameter of foam bead in cutting plane

x :

Position of mean line with respect to the cutting line

Ө :

Deflection of the foam bead before cutting

f :

Effective feed(mm/teeth)

F :

Linear feed(mm/min)

N :

Spindle speed(rpm)

Z :

Number of teeth

References

  1. Li S, Wang X, Xie L, Pang S (2015) The milling – milling machining method and its realization. Int J Adv Manuf Technol 76:1151–1161. https://doi.org/10.1007/s00170-014-6345-y

    Article  Google Scholar 

  2. Santos MC, Machado AR, Sales WF (2016) Machining of aluminum alloys : a review. Int J Adv Manuf Technol 86:3067–3080. https://doi.org/10.1007/s00170-016-8431-9

    Article  Google Scholar 

  3. Saptaji K, Gebremariam MA, Azhari MABM (2018) Machining of biocompatible materials : a review. Int J Adv Manuf Technol 97:2255–2292. https://doi.org/10.1007/s00170-018-1973-2

    Article  Google Scholar 

  4. Benardos P, Vosniakos GC (2003) Predicting surface roughness in machining : a review. Int J Mach Tools Manuf 48:833–844. https://doi.org/10.1016/S0890-6955(03)00059-2

    Article  Google Scholar 

  5. Petkov KP, Hattel JH (2017) Hot-blade cutting of EPS foam for double-curved surfaces—numerical simulation and experiments. Int J Adv Manuf Technol 93:4253–4264. https://doi.org/10.1007/s00170-017-0807-y

    Article  Google Scholar 

  6. Luo H, Liu X, Wang Po (2021) Study on mechanical properties of lost foam pattern in machining. Key Eng Mater. https://doi.org/10.4028/www.scientific.net/KEM.904.148

    Article  Google Scholar 

  7. Dongxia Y, Zhongde S, Feng L, Zhiquan Z (2014) The impact of the cutting process on the dimensional accuracy of expendable patterns. AMR 971–973:291–294. https://doi.org/10.4028/www.scientific.net/AMR.971-973.291

    Article  Google Scholar 

  8. Chen H, Shan Z, Dong H (2013) Research of foam pattern processing for lost foam casting. AMM 331:600–603. https://doi.org/10.4028/www.scientific.net/AMM.331.600

    Article  Google Scholar 

  9. Karunakaran KP, Agrawal S, Vengurlekar PD, Sahasrabudhe OS, Pushpa V, Ely RH (2005) Segmented object manufacturing. IIE Trans 37:291–302. https://doi.org/10.1080/07408170590516999

    Article  Google Scholar 

  10. Paquet E, Bernard A (2021) Foam additive manufacturing technology: main characteristics and experiments for hull mold manufacturing. Rapid Prototyp J 27(8):1489–1500. https://doi.org/10.1108/RPJ-06-2020-0137

    Article  Google Scholar 

  11. Aitchison DR, Brooks HL, Bain JD, Pons D (2011) Rapid manufacturing facilitation through optimal machining prediction of polystyrene foam. Virtual Phys Prototyp 6:41–46. https://doi.org/10.1080/17452759.2010.533961

    Article  Google Scholar 

  12. Gote G, Kamble P, Kori S, Karunakaran KP (2020) Process optimization of segmented object manufacturing for expendable polystyrene foam. In: Praveen Kumar A, Dirgantara T, Krishna PV (eds) Advances in lightweight materials and structures. Springer Proceed Mater 8:695–704. https://doi.org/10.1007/978-981-15-7827-4_71

  13. Sandhu K, Singh G, Singh S, Kumar R (2020) Surface characteristics of machined polystyrene with 3D printed thermoplastic tool. Materials 13:1–16. https://doi.org/10.3390/ma13122729

    Article  Google Scholar 

  14. Malak SF, Anderson AI (2005) Orthogonal cutting of polyurethane foam. Int J Mech Sci 47:867–883. https://doi.org/10.1016/j.ijmecsci.2005.02.002

    Article  Google Scholar 

  15. Brown CA, Brown CA (2011) Issues in modeling machined surface textures. Mach Sci Technol 4–3:539–546. https://doi.org/10.1080/10940340008945721

    Article  Google Scholar 

  16. Ahmann KF, Kapoor SG, Devor RE, Lazoglu I (1997) Machining process modeling. J Manuf Sci Eng 119(4B):655–663. https://doi.org/10.1115/1.2836805

    Article  Google Scholar 

  17. Vaitkus S, Laukaitis A, Gnipas I, Keršulis V, Vėjelis S (2006) Experimental analysis of structure and deformation mechanisms of expanded polystyrene (EPS) slabs. Mater Sci 12:323–327. ISSN 1392–1320

  18. Rossacci J, Shivkumar S (2003) Bead fusion in polystyrene foams. J Mater Sci 38:201–206. https://doi.org/10.1023/A:1021180608531

    Article  Google Scholar 

  19. Wang R, Wang B, Barber GC, Jie Gu, David Schall J (2019) Models for prediction of surface roughness in a face milling process using triangular inserts. Lubricants 7(1):2–14. https://doi.org/10.3390/lubricants7010009

    Article  Google Scholar 

  20. Gadelmawla ES, Koura MM, Maksoud TMA, Elewa IM, Soliman HH (2002) Roughness parameters. J Mater Process Technol 123:133–145. https://doi.org/10.1016/S0924-0136(02)00060-2

    Article  Google Scholar 

  21. Su H, Yang C, Gao S, Fu Y, Ding W (2019) A predictive model on surface roughness during internal traverse grinding of small holes. Int J Adv Manuf Technol 103:2069–2077. https://doi.org/10.1007/s00170-019-03643-z

    Article  Google Scholar 

Download references

Acknowledgements

The authors would like to acknowledge the support from the MHRD UAY 005 project. The authors would also like to thank the late Mr. Sunil Mohite, proprietor of JMT, Mumbai, for his guidance and Mr. Prashant Chaurasia, a research scholar at IIT Bombay, for his help.

Funding

Funding is provided by MHRD under UAY-005.

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Indian Institute of Technology Bombay, Mumbai, India, 400076

    Gopal Gote, Pushkar Kamble, Rajendra Hodgir, Yash Mittal & K. P. Karunakaran

Authors
  1. Gopal Gote
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Pushkar Kamble
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Rajendra Hodgir
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Yash Mittal
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. K. P. Karunakaran
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Gopal Gote: conceptualization, validation, and writing original draft, Pushkar Kamble: validation, Rajendra Hodgir: validation, Yash Mittal: conceptualization, validation, K. P. Karunakaran: conceptualization and ideation.

Corresponding author

Correspondence to Gopal Gote.

Ethics declarations

Ethics approval

Not applicable.

Consent to participate

Not applicable.

Consent for publication

All authors agrees to publish this manuscript in International Journal of Advance Manufacturing Technology and Confirms that this work has not been published anywhere before.

Conflict of interest

The authors declare no competing interests.

Additional information

Publisher's note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Gote, G., Kamble, P., Hodgir, R. et al. Mathematical modeling of surface roughness in polystyrene foam machining. Int J Adv Manuf Technol 120, 7461–7475 (2022). https://doi.org/10.1007/s00170-022-09229-6

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-022-09229-6

Keywords

Search

Navigation