Abstract: A three-dimensional numerical simulation of flow
through mini and microchannels with designed roughness is
conducted here. The effect of the roughness height (surface
roughness), geometry, Reynolds number on the friction factor, and
Nusselt number is investigated. The study is carried out by
employing CFD software, CFX. Our work focuses on a water flow
inside a circular mini-channel of 1 mm and microchannels of 500 and
100 m in diameter. The speed entry varies from 0.1 m/s to 20 m/s.
The general trend can be observed that bigger sizes of roughness
element lead to higher flow resistance. It is found that the friction
factor increases in a nonlinear fashion with the increase in obstruction
height. Particularly, the effect of roughness can no longer be ignored
at relative roughness height higher than 3%. A significant increase in
Poiseuille number is detected for all configurations considered. The
same observation can be done for Nusselt number. The transition
zone between laminar and turbulent flow depends on the channel
diameter.
Abstract: An experimental study with four different types of bed
conditions was carried out to understand the effect of roughness in
open channel flow at two different Reynolds numbers. The bed
conditions include a smooth surface and three different roughness
conditions, which were generated using sand grains with a median
diameter of 2.46 mm. The three rough conditions include a surface
with distributed roughness, a surface with continuously distributed
roughness and a sand bed with a permeable interface. A commercial
two-component fibre-optic LDA system was used to conduct the
velocity measurements. The variables of interest include the mean
velocity, turbulence intensity, correlation between the streamwise and
the wall normal turbulence, Reynolds shear stress and velocity triple
products. Quadrant decomposition was used to extract the magnitude
of the Reynolds shear stress of the turbulent bursting events. The
effect of roughness was evident throughout the flow depth. The
results show that distributed roughness has the greatest roughness
effect followed by the sand bed and the continuous roughness.
Compared to the smooth bed, the streamwise turbulence intensity
reduces but the vertical turbulence intensity increases at a location
very close to the bed due to the introduction of roughness. Although
the same sand grain is used to create the three different rough bed
conditions, the difference in the turbulence intensity is an indication
that the specific geometry of the roughness has an influence on
turbulence structure.
Abstract: These Monolayer and multilayer coatings of CrN and
AlCrN deposited on 100Cr6 (AISI 52100) substrate by PVD
magnetron sputtering system. The microstructures of the coatings
were characterized using atomic force microscopy (AFM). The AFM
analysis revealed the presence of domes and craters that are
uniformly distributed over all surfaces of the various layers.
Nanoindentation measurement of CrN coating showed maximum
hardness (H) and modulus (E) of 14 GPa and 190 GPa, respectively.
The measured H and E values of AlCrN coatings were found to be 30
GPa and 382 GPa, respectively. The improved hardness in both the
coatings was attributed mainly to a reduction in crystallite size and
decrease in surface roughness. The incorporation of Al into the CrN
coatings has improved both hardness and Young’s modulus.
Abstract: This study investigates the effects of the lead angle
and chip thickness variation on surface roughness during the
machining of compacted graphite iron using ceramic cutting tools
under dry cutting conditions. Analytical models were developed for
predicting the surface roughness values of the specimens after the
face milling process. Experimental data was collected and imported
to the artificial neural network model. A multilayer perceptron model
was used with the back propagation algorithm employing the input
parameters of lead angle, cutting speed and feed rate in connection
with chip thickness. Furthermore, analysis of variance was employed
to determine the effects of the cutting parameters on surface
roughness. Artificial neural network and regression analysis were
used to predict surface roughness. The values thus predicted were
compared with the collected experimental data, and the
corresponding percentage error was computed. Analysis results
revealed that the lead angle is the dominant factor affecting surface
roughness. Experimental results indicated an improvement in the
surface roughness value with decreasing lead angle value from 88° to
45°.
Abstract: In the present study, response surface methodology has been used to optimize turn-assisted deep cold rolling process of AISI 4140 steel. A regression model is developed to predict surface hardness and surface roughness using response surface methodology and central composite design. In the development of predictive model, deep cold rolling force, ball diameter, initial roughness of the workpiece, and number of tool passes are considered as model variables. The rolling force and the ball diameter are the significant factors on the surface hardness and ball diameter and numbers of tool passes are found to be significant for surface roughness. The predicted surface hardness and surface roughness values and the subsequent verification experiments under the optimal operating conditions confirmed the validity of the predicted model. The absolute average error between the experimental and predicted values at the optimal combination of parameter settings for surface hardness and surface roughness is calculated as 0.16% and 1.58% respectively. Using the optimal processing parameters, the surface hardness is improved from 225 to 306 HV, which resulted in an increase in the near surface hardness by about 36% and the surface roughness is improved from 4.84µm to 0.252 µm, which resulted in decrease in the surface roughness by about 95%. The depth of compression is found to be more than 300µm from the microstructure analysis and this is in correlation with the results obtained from the microhardness measurements. Taylor hobson talysurf tester, micro vickers hardness tester, optical microscopy and X-ray diffractometer are used to characterize the modified surface layer.
Abstract: Non-water based fixed abrasive polishing was adopted
to manufacture LBO crystal for nano precision surface quality because
of its deliquescent. Ethyl alcohol was selected as the non-water based
slurry solvent and ethanediamine, lactic acid, hydrogen peroxide was
added in the slurry as a chemical additive, respectively. Effect of
different additives with non-water based slurry on material removal
rate, surface topography, microscopic appearances, and surface
roughness were investigated in fixed abrasive polishing of LBO
crystal. The results show the best surface quality of LBO crystal with
surface roughness Sa 8.2 nm and small damages was obtained by
non-water based slurry with lactic acid. Non-water based fixed
abrasive polishing can achieve nano precision surface quality of LBO
crystal with high material removal.
Abstract: In this study, a computational fluid dynamics (CFD)
model has been developed for studying the effect of surface
roughness profile on the EHL problem. The cylinders contact
geometry, meshing and calculation of the conservation of mass and
momentum equations are carried out using the commercial software
packages ICEMCFD and ANSYS Fluent. The user defined functions
(UDFs) for density, viscosity and elastic deformation of the cylinders
as the functions of pressure and temperature are defined for the CFD
model. Three different surface roughness profiles are created and
incorporated into the CFD model. It is found that the developed CFD
model can predict the characteristics of fluid flow and heat transfer in
the EHL problem, including the main parameters such as pressure
distribution, minimal film thickness, viscosity, and density changes.
The results obtained show that the pressure profile at the center of the
contact area directly relates to the roughness amplitude. A rough
surface with kurtosis value of more than 3 has greater influence over
the fluctuated shape of pressure distribution than in other cases.
Abstract: Numerical studies were conducted using Lattice
Boltzmann Method (LBM) to study the natural convection in a square
cavity in the presence of roughness. An algorithm based on a single
relaxation time Bhatnagar-Gross-Krook (BGK) model of Lattice
Boltzmann Method (LBM) was developed. Roughness was
introduced on both the hot and cold walls in the form of sinusoidal
roughness elements. The study was conducted for a Newtonian fluid
of Prandtl number (Pr) 1.0. The range of Ra number was explored
from 10^3 to 10^6 in a laminar region. Thermal and hydrodynamic
behavior of fluid was analyzed using a differentially heated square
cavity with roughness elements present on both the hot and cold wall.
Neumann boundary conditions were introduced on horizontal walls
with vertical walls as isothermal. The roughness elements were at the
same boundary condition as corresponding walls. Computational
algorithm was validated against previous benchmark studies
performed with different numerical methods, and a good agreement
was found to exist. Results indicate that the maximum reduction in
the average heat transfer was 16.66 percent at Ra number 10^5.
Abstract: This paper proposes a rotational invariant texture
feature based on the roughness property of the image for psoriasis
image analysis. In this work, we have applied this feature for image
classification and segmentation. The fuzzy concept is employed to
overcome the imprecision of roughness. Since the psoriasis lesion is
modeled by a rough surface, the feature is extended for calculating
the Psoriasis Area Severity Index value. For classification and
segmentation, the Nearest Neighbor algorithm is applied. We have
obtained promising results for identifying affected lesions by using
the roughness index and severity level estimation.
Abstract: Solar energy is a good option among renewable
energy resources due to its easy availability and abundance. The
simplest and most efficient way to utilize solar energy is to convert it
into thermal energy and this can be done with the help of solar
collectors. The thermal performance of such collectors is poor due to
less heat transfer from the collector surface to air. In this work,
experimental investigations of single pass solar air heater having
triangular duct and provided with roughness element on the underside
of the absorber plate. V-shaped ribs are used for investigation having
three different values of relative roughness pitch (p/e) ranges from 4-
16 for a fixed value of angle of attack (α), relative roughness height
(e/Dh) and a relative gap distance (d/x) values are 60°, 0.044 and 0.60
respectively. Result shows that considerable augmentation in heat
transfer has been obtained by providing roughness.
Abstract: Burnishing is increasingly used as a finishing operation to improve surface roughness and surface hardness. This can be achieved by applying a hard ball or roller onto metallic surfaces under pressure, in order to achieve many advantages in the metallic surface. In the present work, the feed rate, speed and force have been considered as the basic burnishing parameters to study the surface roughness and surface hardness of metallic matrix composites. The considered metal matrix composites were made from Aluminum-Magnesium-Graphite with five different weight percentage of graphite. Both effects of burnishing parameters mentioned above and the graphite percentage on the surface hardness and surface roughness of the metallic matrix composites were studied. The results of this investigation showed that the surface hardness of the metallic composites increases with the increase of the burnishing force and decreases with the increase in the burnishing feed rate and burnishing speed. The surface roughness of the metallic composites decreases with the increasing of the burnishing force, feed rate, and speed to certain values, then it starts to increase. On the other hand, the increase in the weight percentage of the graphite in the considered composites causes a decrease in the surface hardness and an increase in the surface roughness.
Abstract: In this research, waterglass based aerogel powder was
prepared by sol–gel process and ambient pressure drying. Inspired by
limited dust releasing, aerogel powder was introduced to the PET
electrospinning solution in an attempt to create required bulk and
surface structure for the nanofibers to improve their hydrophobic and
insulation properties. The samples evaluation was carried out by
measuring density, porosity, contact angle, heat transfer, FTIR, BET,
and SEM. According to the results, porous silica aerogel powder was
fabricated with mean pore diameter of 24 nm and contact angle of
145.9º. The results indicated the usefulness of the aerogel powder
confined into nanofibers to control surface roughness for
manipulating superhydrophobic nanowebs with water contact angle
of 147º. It can be due to a multi-scale surface roughness which was
created by nanowebs structure itself and nanofibers surface
irregularity in presence of the aerogels while a layer of fluorocarbon
created low surface energy. The wettability of a solid substrate is an
important property that is controlled by both the chemical
composition and geometry of the surface. Also, a decreasing trend in
the heat transfer was observed from 22% for the nanofibers without
any aerogel powder to 8% for the nanofibers with 4% aerogel
powder. The development of thermal insulating materials has become
increasingly more important than ever in view of the fossil energy
depletion and global warming that call for more demanding energysaving
practices.
Abstract: Machining parameters are very important in
determining the surface quality of any material. In the past decade,
some new engineering materials were developed for the
manufacturing industry which created a need to conduct an
investigation on the impact of the said parameters on their surface
roughness. Polyurethane (PU) block is widely used in the automotive
industry to manufacture parts such as checking fixtures that are used
to verify the dimensional accuracy of automotive parts. In this paper,
the design of experiment (DOE) was used to investigate on the effect
of the milling parameters on the PU block. Furthermore, an analysis
of the machined surface chemical composition was done using
scanning electron microscope (SEM). It was found that the surface
roughness of the PU block is severely affected when PU undergoes a
flood machining process instead of a dry condition. In addition the
stepover and the silicon content were found to be the most significant
parameters that influence the surface quality of the PU block.
Abstract: This study presents a cost-effective approach for rapid
fabricating modeling platforms utilized in fused deposition modeling
system. A small-batch production of modeling platforms about 20
pieces can be obtained economically through silicone rubber mold
using vacuum casting without applying the plastic injection molding.
The air venting systems is crucial for fabricating modeling platform
using vacuum casting. Modeling platforms fabricated can be used for
building rapid prototyping model after sandblasting. This study offers
industrial value because it has both time-effectiveness and
cost-effectiveness.
Abstract: The quality of machined surfaces is an important characteristic of cutting processes and surface roughness has strong effects on the performance of sliding, moving components. The ability to forecast these values for a given process has been of great interests among researchers for a long time. Different modeling procedures and algorithms have been worked-out, and each has its own advantages and drawbacks. A new method will be introduced in this paper which will make it possible to calculate both the profile (2D) and surface (3D) parameters of theoretical roughness in the face milling of plain surfaces. This new method is based on an expediently developed CAD model, and uses a professional program for the roughness evaluation. Cutting experiments were performed on 42CrMo4 specimens in order to validate the accuracy of the model. The results have revealed that the method is able to predict surface roughness with good accuracy.
Abstract: Electrical discharge machining (EDM) is a relatively modern machining process having distinct advantages over other machining processes and can machine Ti-alloys effectively. The present study emphasizes the features of the development of regression equation based on response surface methodology (RSM) for correlating the interactive and higher-order influences of machining parameters on surface finish of Titanium alloy Ti-6Al-4V. The process parameters selected in this study are discharge current, pulse on time, pulse off time and servo voltage. Machining has been accomplished using negative polarity of Graphite electrode. Analysis of variance is employed to ascertain the adequacy of the developed regression model. Experiments based on central composite of response surface method are carried out. Scanning electron microscopy (SEM) analysis was performed to investigate the surface topography of the EDMed job. The results evidence that the proposed regression equation can predict the surface roughness effectively. The lower ampere and short pulse on time yield better surface finish.
Abstract: Simultaneous measurements of the curves for wear versus distance, wear rate versus distance, and coefficient of friction versus distance were performed in situ to distinguish the transition from severe running-in wear to mild wear. The effects of the initial surface roughness on the severe running-in wear volume were investigated. Disk-on-plate friction and wear tests were carried out with SUS304 austenitic stainless steel in contact with itself under repeated dry sliding conditions at room temperature. The wear volume was dependent on the initial surface roughness. The wear volume when the initial surfaces on the plate and disk had dissimilar roughness was lower than that when these surfaces had similar roughness. For the dissimilar roughness, the wear volume decreased with decreasing initial surface roughness and reached a minimum; it stayed nearly constant as the roughness was less than the mean size of the oxide particles.
Abstract: In this paper a simple terrain evaluation method for
hexapod robot is introduced. This method is based on feet coordinate
evaluation when all are on the ground. Depending on the feet
coordinate differences the local terrain evaluation is possible. Terrain
evaluation is necessary for right gait selection and/or body position
correction. For terrain roughness evaluation three planes are plotted:
two of them as definition points use opposite feet coordinates, third
coincides with the robot body plane. The leaning angle of body plane
is evaluated measuring gravity force using three-axis accelerometer.
Terrain roughness evaluation method is based on angle estimation
between normal vectors of these planes. Aim of this work is to
present a simple method for embedded robot controller, allowing to
find the best further movement settings.
Abstract: Production of hard-to-cut materials with uncoated carbide cutting tools in turning, not only cause tool life reduction but also, impairs the product surface roughness. In this paper, influence of hot machining method were studied and presented in two cases. Case1-Workpiece surface roughness quality with constant cutting parameter and 300 ºC initial workpiece surface temperature. Case 2- Tool temperature variation when cutting with two speeds 78.5 (m/min) and 51 (m/min). The workpiece material and tool used in this study were AISI 1060 steel (45HRC) and uncoated carbide TNNM 120408-SP10(SANDVIK Coromant) respectively. A gas flam heating source was used to preheating of the workpiece surface up to 300 ºC, causing reduction of yield stress about 15%. Results obtained experimentally, show that the method used can considerably improved surface quality of the workpiece.
Abstract: Minimum Quantity Lubrication (MQL) technique
obtained a significant attention in machining processes to reduce
environmental loads caused by usage of conventional cutting fluids.
Recently nanofluids are finding an extensive application in the field
of mechanical engineering because of their superior lubrication and
heat dissipation characteristics. This paper investigates the use of a
nanofluid under MQL mode to improve grinding characteristics of
Ti-6Al-4V alloy. Taguchi-s experimental design technique has been
used in the present investigation and a second order model has been
established to predict grinding forces and surface roughness.
Different concentrations of water based Al2O3 nanofluids were
applied in the grinding operation through MQL setup developed in
house and the results have been compared with those of conventional
coolant and pure water. Experimental results showed that grinding
forces reduced significantly when nano cutting fluid was used even at
low concentration of the nano particles and surface finish has been
found to improve with higher concentration of the nano particles.