Abstract: Response surface methodology with Box–Benhken (BB) design of experiment approach has been utilized to study the mechanism of interface slip damping in layered and jointed tack welded beams with varying surface roughness. The design utilizes the initial amplitude of excitation, tack length and surface roughness at the interfaces to develop the model for the logarithmic damping decrement of the layered and jointed welded structures. Statistically designed experiments have been performed to estimate the coefficients in the mathematical model, predict the response, and check the adequacy of the model. Comparison of predicted and experimental response values outside the design conditions have shown good correspondence, implying that empirical model derived from response surface approach can be effectively used to describe the mechanism of interface slip damping in layered and jointed tack welded structures.
Abstract: FW4 is a newly developed hot die material widely
used in Forging Dies manufacturing. The right selection of the
machining conditions is one of the most important aspects to take
into consideration in the Electrical Discharge Machining (EDM) of
FW4. In this paper an attempt has been made to develop
mathematical models for relating the Material Removal Rate (MRR),
Tool Wear Ratio (TWR) and surface roughness (Ra) to machining
parameters (current, pulse-on time and voltage). Furthermore, a study
was carried out to analyze the effects of machining parameters in
respect of listed technological characteristics. The results of analysis
of variance (ANOVA) indicate that the proposed mathematical
models, can adequately describe the performance within the limits of
the factors being studied.
Abstract: Covering-based rough sets is an extension of rough
sets and it is based on a covering instead of a partition of the
universe. Therefore it is more powerful in describing some practical
problems than rough sets. However, by extending the rough sets,
covering-based rough sets can increase the roughness of each model
in recognizing objects. How to obtain better approximations from
the models of a covering-based rough sets is an important issue.
In this paper, two concepts, determinate elements and indeterminate
elements in a universe, are proposed and given precise definitions
respectively. This research makes a reasonable refinement of the
covering-element from a new viewpoint. And the refinement may
generate better approximations of covering-based rough sets models.
To prove the theory above, it is applied to eight major coveringbased
rough sets models which are adapted from other literature.
The result is, in all these models, the lower approximation increases
effectively. Correspondingly, in all models, the upper approximation
decreases with exceptions of two models in some special situations.
Therefore, the roughness of recognizing objects is reduced. This
research provides a new approach to the study and application of
covering-based rough sets.
Abstract: The flow field over a three dimensional pole barn
characterized by a cylindrical roof has been numerically investigated.
Wind pressure and viscous loads acting on the agricultural building
have been analyzed for several incoming wind directions, so as to
evaluate the most critical load condition on the structure. A constant
wind velocity profile, based on the maximum reference wind speed in
the building site (peak gust speed worked out for 50 years return
period) and on the local roughness coefficient, has been simulated.
In order to contemplate also the hazard due to potential air
wedging between the stored hay and the lower part of the ceiling, the
effect of a partial filling of the barn has been investigated.
The distribution of wind-induced loads on the structure have been
determined, allowing a numerical quantification of the effect of wind
direction on the induced stresses acting on a hemicylindrical roof.
Abstract: This paper presents the idea of a rough controller with application to control the overhead traveling crane system. The structure of such a controller is based on a suggested concept of a fuzzy logic controller. A measure of fuzziness in rough sets is introduced. A comparison between fuzzy logic controller and rough controller has been demonstrated. The results of a simulation comparing the performance of both controllers are shown. From these results we infer that the performance of the proposed rough controller is satisfactory.
Abstract: In this paper, the wear of high speed steel hobs during
hobbing has been studied. The wear mechanisms are strongly
influenced by the choice of cutting speed. At moderate and high
cutting speeds three major wear mechanisms were identified:
abrasion, mild adhesive and severe adhesive. The microstructure and
wear behavior of two high speed steel grades (M2 and ASP30) has
been compared. In contrast, a variation in chemical composition or
microstructure of HSS tool material generally did not change the
dominant wear mechanism. However, the tool material properties
determine the resistance against the operating wear mechanism and
consequently the tool life. The metallographic analysis and wear
measurement at the tip of hob teeth included scanning electron
microscopy and stereoscope microscopy. Roughness profilometery is
used for measuring the gear surface roughness.
Abstract: This paper presents an advance in monitoring and
process control of surface roughness in CNC machine for the turning
and milling processes. An integration of the in-process monitoring
and process control of the surface roughness is proposed and
developed during the machining process by using the cutting force
ratio. The previously developed surface roughness models for turning
and milling processes of the author are adopted to predict the inprocess
surface roughness, which consist of the cutting speed, the
feed rate, the tool nose radius, the depth of cut, the rake angle, and
the cutting force ratio. The cutting force ratios obtained from the
turning and the milling are utilized to estimate the in-process surface
roughness. The dynamometers are installed on the tool turret of CNC
turning machine and the table of 5-axis machining center to monitor
the cutting forces. The in-process control of the surface roughness
has been developed and proposed to control the predicted surface
roughness. It has been proved by the cutting tests that the proposed
integration system of the in-process monitoring and the process
control can be used to check the surface roughness during the cutting
by utilizing the cutting force ratio.
Abstract: The previous study of new metal gasket that contact
width and contact stress an important design parameter for optimizing
metal gasket performance. The optimum design based on an elastic
and plastic contact stress was founded. However, the influence of
flange surface roughness had not been investigated thoroughly. The
flange has many kinds of surface roughness. In this study, we
conducted a gasket model include a flange surface roughness effect. A
finite element method was employed to develop simulation solution. A
uniform quadratic mesh used for meshing the gasket material and a
gradually quadrilateral mesh used for meshing the flange. The gasket
model was simulated by using two simulation stages which is forming
and tightening simulation. A simulation result shows that a smoother
of surface roughness has higher slope for force per unit length. This
mean a squeezed against between flange and gasket will be strong. The
slope of force per unit length for gasket 400-MPa mode was higher
than the gasket 0-MPa mode.
Abstract: The objective of this research was to study factors,
which were affected on surface roughness in high speed milling of
hardened tool steel. Material used in the experiment was tool steel JIS
SKD 61 that hardened on 60 ±2 HRC. Full factorial experimental
design was conducted on 3 factors and 3 levels (3
3
designs) with 2
replications. Factors were consisted of cutting speed, feed rate, and
depth of cut. The results showed that influenced factor affected to
surface roughness was cutting speed, feed rate and depth of cut which
showed statistical significant. Higher cutting speed would cause on
better surface quality. On the other hand, higher feed rate would cause
on poorer surface quality. Interaction of factor was found that cutting
speed and depth of cut were significantly to surface quality. The
interaction of high cutting speed associated with low depth of cut
affected to better surface quality than low cutting speed and high depth
of cut.
Abstract: Electrical Discharge Machine (EDM) is especially
used for the manufacturing of 3-D complex geometry and hard
material parts that are extremely difficult-to-machine by conventional
machining processes. In this paper authors review the research work
carried out in the development of die-sinking EDM within the past
decades for the improvement of machining characteristics such as
Material Removal Rate, Surface Roughness and Tool Wear Ratio. In
this review various techniques reported by EDM researchers for
improving the machining characteristics have been categorized as
process parameters optimization, multi spark technique, powder
mixed EDM, servo control system and pulse discriminating. At the
end, flexible machine controller is suggested for Die Sinking EDM to
enhance the machining characteristics and to achieve high-level
automation. Thus, die sinking EDM can be integrated with Computer
Integrated Manufacturing environment as a need of agile
manufacturing systems.
Abstract: One of the main research directions in CAD/CAM
machining area is the reducing of machining time.
The feedrate scheduling is one of the advanced techniques that
allows keeping constant the uncut chip area and as sequel to keep
constant the main cutting force. They are two main ways for feedrate
optimization. The first consists in the cutting force monitoring, which
presumes to use complex equipment for the force measurement and
after this, to set the feedrate regarding the cutting force variation. The
second way is to optimize the feedrate by keeping constant the
material removal rate regarding the cutting conditions.
In this paper there is proposed a new approach using an extended
database that replaces the system model.
The feedrate scheduling is determined based on the identification
of the reconfigurable machine tool, and the feed value determination
regarding the uncut chip section area, the contact length between tool
and blank and also regarding the geometrical roughness.
The first stage consists in the blank and tool monitoring for the
determination of actual profiles. The next stage is the determination
of programmed tool path that allows obtaining the piece target
profile.
The graphic representation environment models the tool and blank
regions and, after this, the tool model is positioned regarding the
blank model according to the programmed tool path. For each of
these positions the geometrical roughness value, the uncut chip area
and the contact length between tool and blank are calculated. Each of
these parameters are compared with the admissible values and
according to the result the feed value is established.
We can consider that this approach has the following advantages:
in case of complex cutting processes the prediction of cutting force is
possible; there is considered the real cutting profile which has
deviations from the theoretical profile; the blank-tool contact length
limitation is possible; it is possible to correct the programmed tool
path so that the target profile can be obtained.
Applying this method, there are obtained data sets which allow the
feedrate scheduling so that the uncut chip area is constant and, as a
result, the cutting force is constant, which allows to use more
efficiently the machine tool and to obtain the reduction of machining
time.
Abstract: The aim of this research is to evaluate surface
roughness and develop a multiple regression model for surface roughness as a function of cutting parameters during the turning of
flame hardened medium carbon steel with TiN-Al2O3-TiCN coated inserts. An experimental plan of work and signal-to-noise ratio (S/N)
were used to relate the influence of turning parameters to the
workpiece surface finish utilizing Taguchi methodology. The effects
of turning parameters were studied by using the analysis of variance (ANOVA) method. Evaluated parameters were feed, cutting speed,
and depth of cut. It was found that the most significant interaction among the considered turning parameters was between depth of cut and feed. The average surface roughness (Ra) resulted by TiN-Al2O3-
TiCN coated inserts was about 2.44 μm and minimum value was 0.74 μm. In addition, the regression model was able to predict values for surface roughness in comparison with experimental values within
reasonable limit.
Abstract: ZnO-SnO2 i.e. Zinc-Tin-Oxide (ZTO) thin films were
deposited on glass substrate with varying concentrations (ZnO:SnO2
- 100:0, 90:10, 70:30 and 50:50 wt.%) at room temperature by flash
evaporation technique. These deposited ZTO film were annealed at
450 0C in vacuum. These films were characterized to study the effect
of annealing on the structural, electrical, and optical properties.
Atomic force microscopy (AFM) and Scanning electron microscopy
(SEM) images manifest the surface morphology of these ZTO thin
films. The apparent growth of surface features revealed the formation
of nanostructure ZTO thin films. The small value of surface
roughness (root mean square RRMS) ensures the usefulness in
optical coatings. The sheet resistance was also found to be decreased
for both types of films with increasing concentration of SnO2. The
optical transmittance found to be decreased however blue shift has
been observed after annealing.
Abstract: End milling process is one of the common metal
cutting operations used for machining parts in manufacturing
industry. It is usually performed at the final stage in manufacturing a
product and surface roughness of the produced job plays an
important role. In general, the surface roughness affects wear
resistance, ductility, tensile, fatigue strength, etc., for machined parts
and cannot be neglected in design. In the present work an
experimental investigation of end milling of aluminium alloy with
carbide tool is carried out and the effect of different cutting
parameters on the response are studied with three-dimensional
surface plots. An artificial neural network (ANN) is used to establish
the relationship between the surface roughness and the input cutting
parameters (i.e., spindle speed, feed, and depth of cut). The Matlab
ANN toolbox works on feed forward back propagation algorithm is
used for modeling purpose. 3-12-1 network structure having
minimum average prediction error found as best network architecture
for predicting surface roughness value. The network predicts surface
roughness for unseen data and found that the result/prediction is
better. For desired surface finish of the component to be produced
there are many different combination of cutting parameters are
available. The optimum cutting parameter for obtaining desired
surface finish, to maximize tool life is predicted. The methodology is
demonstrated, number of problems are solved and algorithm is coded
in Matlab®.
Abstract: This study was aimed to explain the influence of surface roughness of the drawbead on non-symmetry deep drawing cold rolled steel sheet to improve the drawability of cold rolled steel sheet. The variables used in this study included semi-circle drawbead with 3 levels of surface roughness which are 6.127 mm Ra, 0.963 mm Ra and 0.152 mm Ra and cold rolled steel sheet according to 3 grades of the JIS standards which are SPCC, SPCE and SPCD with the thickness of 1.0 mm and the blankholder force which is 50% of the drawing force and the depth of 50 mm. According to the test results, when there was the increase in the surface roughness of drawbead, there would be the increase in deep drawing force, especially the SPCC cold rolled steel sheet. This is similar to the increase in the equivalent strain and the wall thickness distribution when the surface roughness of the drawbead increased. It could be concluded that the surface roughness of drawbead has an influence on deep drawing cold rolled steel sheet, especially the drawing force, the equivalent strain and the wall thickness distribution.
Abstract: In this study, a nickel film with nano-crystalline grains,
high hardness and smooth surface was electrodeposited using a post
supercritical carbon dioxide (CO2) mixed Watts electrolyte. Although
the hardness was not as high as its Sc-CO2 counterpart, the thin coating
contained significantly less number of nano-sized pinholes. By
measuring the escape concentration of the dissolved CO2 in post
Sc-CO2 mixed electrolyte with the elapsed time, it was believed that
the residue of dissolved CO2 bubbles should closely relate to the
improvement in hardness and surface roughness over its conventional
plating counterpart. Therefore, shortening the duration of
electroplating with the raise of current density up to 0.5 A/cm2 could
effectively retain more post Sc-CO2 mixing effect. This study not only
confirms the roles of dissolved CO2 bubbles in electrolyte but also
provides a potential process to overcome most issues associated with
the cost in building high-pressure chamber for large size products and
continuous plating using supercritical method.
Abstract: Industrial surveys shows that manufacturing
companies define the qualities of thermal removing process based on
the dimension and physical appearance of the cutting material
surface. Therefore, the roughness of the surface area of the material
cut by the plasma arc cutting process and the rate of the removed
material by the manual plasma arc cutting machine was importantly
considered. Plasma arc cutter Selco Genesis 90 was used to cut
Standard AISI 1017 Steel of 200 mm x100 mm x 6 mm manually
based on the selected parameters setting. The material removal rate
(MRR) was measured by determining the weight of the specimens
before and after the cutting process. The surface roughness (SR)
analysis was conducted using Mitutoyo CS-3100 to determine the
average roughness value (Ra). Taguchi method was utilized to
achieve optimum condition for both outputs studied. The
microstructure analysis in the region of the cutting surface is
performed using SEM. The results reveal that the SR values are
inversely proportional to the MRR values. The quality of the surface
roughness depends on the dross peak that occurred after the cutting
process.
Abstract: The quality of a machined surface is becoming more and more important to justify the increasing demands of sophisticated component performance, longevity, and reliability. Usually, any machining operation leaves its own characteristic evidence on the machined surface in the form of finely spaced micro irregularities (surface roughness) left by the associated indeterministic characteristics of the different elements of the system: tool-machineworkpart- cutting parameters. However, one of the most influential sources in machining affecting surface roughness is the instantaneous state of tool edge. The main objective of the current work is to relate the in-process immeasurable cutting edge deformation and surface roughness to a more reliable easy-to-measure force signals using a robust non-linear time-dependent modeling regression techniques. Time-dependent modeling is beneficial when modern machining systems, such as adaptive control techniques are considered, where the state of the machined surface and the health of the cutting edge are monitored, assessed and controlled online using realtime information provided by the variability encountered in the measured force signals. Correlation between wear propagation and roughness variation is developed throughout the different edge lifetimes. The surface roughness is further evaluated in the light of the variation in both the static and the dynamic force signals. Consistent correlation is found between surface roughness variation and tool wear progress within its initial and constant regions. At the first few seconds of cutting, expected and well known trend of the effect of the cutting parameters is observed. Surface roughness is positively influenced by the level of the feed rate and negatively by the cutting speed. As cutting continues, roughness is affected, to different extents, by the rather localized wear modes either on the tool nose or on its flank areas. Moreover, it seems that roughness varies as wear attitude transfers from one mode to another and, in general, it is shown that it is improved as wear increases but with possible corresponding workpart dimensional inaccuracy. The dynamic force signals are found reasonably sensitive to simulate either the progressive or the random modes of tool edge deformation. While the frictional force components, feeding and radial, are found informative regarding progressive wear modes, the vertical (power) components is found more representative carrier to system instability resulting from the edge-s random deformation.
Abstract: Adhesion strength of exterior or interior coating of
steel pipes is too important. Increasing of coating adhesion on
surfaces can increase the life time of coating, safety factor of
transmitting line pipe and decreasing the rate of corrosion and costs.
Preparation of steel pipe surfaces before doing the coating process is
done by shot and grit blasting. This is a mechanical way to do it.
Some effective parameters on that process, are particle size of
abrasives, distance to surface, rate of abrasive flow, abrasive physical
properties, shapes, selection of abrasive, kind of machine and its
power, standard of surface cleanness degree, roughness, time of
blasting and weather humidity. This search intended to find some
better conditions which improve the surface preparation, adhesion
strength and corrosion resistance of coating. So, this paper has
studied the effect of varying abrasive flow rate, changing the
abrasive particle size, time of surface blasting on steel surface
roughness and over blasting on it by using the centrifugal blasting
machine. After preparation of numbers of steel samples (according to
API 5L X52) and applying epoxy powder coating on them, to
compare strength adhesion of coating by Pull-Off test. The results
have shown that, increasing the abrasive particles size and flow rate,
can increase the steel surface roughness and coating adhesion
strength but increasing the blasting time can do surface over blasting
and increasing surface temperature and hardness too, change,
decreasing steel surface roughness and coating adhesion strength.
Abstract: In this paper, Zinc Oxide (ZnO) thin films are deposited on glass substrate by sol-gel method. The ZnO thin films with well defined orientation were acquired by spin coating of zinc acetate dehydrate monoethanolamine (MEA), de-ionized water and isopropanol alcohol. These films were pre-heated at 275°C for 10 min and then annealed at 350°C, 450°C and 550°C for 80 min. The effect of annealing temperature and different thickness on structure and surface morphology of the thin films were verified by Atomic Force Microscopy (AFM). It was found that there was a significant effect of annealing temperature on the structural parameters of the films such as roughness exponent, fractal dimension and interface width. Thin films also were characterizied by X-ray Diffractometery (XRD) method. XRD analysis revealed that the annealed ZnO thin films consist of single phase ZnO with wurtzite structure and show the c-axis grain orientation. Increasing annealing temperature increased the crystallite size and the c-axis orientation of the film after 450°C. Also In this study, ZnO thin films in different thickness have been prepared by sol-gel method on the glass substrate at room temperature. The thicknesses of films are 100, 150 and 250 nm. Using fractal analysis, morphological characteristics of surface films thickness in amorphous state were investigated. The results show that with increasing thickness, surface roughness (RMS) and lateral correlation length (ξ) are decreased. Also, the roughness exponent (α) and growth exponent (β) were determined to be 0.74±0.02 and 0.11±0.02, respectively.