Abstract: In the present work, a study has been made on the combination of the electrical discharge machining (EDM) with ultrasonic vibrations to improve the machining efficiency. In experiments the graphite used as tool electrode and material of workpiece was AISIH13 tool steel. The parameters such as discharge peak current and pulse duration were changed to explore their effect on the material removal rate (MRR), relative tool wear ratio (TWR) and surface roughness. From the experimental result it can be seen that ultrasonic vibration of the workpiece can significantly reduces the inactive pulses and improves the stability of process. It was found that ultrasonic assisted EDM (US-EDM) is effective in attaining a high material removal rate (MRR) in finishing regime.
Abstract: Un-doped GaN film of thickness 1.90 mm, grown on
sapphire substrate were uniformly implanted with 325 keV Mn+ ions
for various fluences varying from 1.75 x 1015 - 2.0 x 1016 ions cm-2 at
3500 C substrate temperature. The structural, morphological and
magnetic properties of Mn ion implanted gallium nitride samples
were studied using XRD, AFM and SQUID techniques. XRD of the
sample implanted with various ion fluences showed the presence of
different magnetic phases of Ga3Mn, Ga0.6Mn0.4 and Mn4N.
However, the compositions of these phases were found to be
depended on the ion fluence. AFM images of non-implanted sample
showed micrograph with rms surface roughness 2.17 nm. Whereas
samples implanted with the various fluences showed the presence of
nano clusters on the surface of GaN. The shape, size and density of
the clusters were found to vary with respect to ion fluence. Magnetic
moment versus applied field curves of the samples implanted with
various fluences exhibit the hysteresis loops. The Curie temperature
estimated from zero field cooled and field cooled curves for the
samples implanted with the fluence of 1.75 x 1015, 1.5 x 1016 and 2.0
x 1016 ions cm-2 was found to be 309 K, 342 K and 350 K
respectively.
Abstract: Turbulence modeling of large-scale flow over a vegetated surface is complex. Such problems involve large scale computational domains, while the characteristics of flow near the surface are also involved. In modeling large scale flow, surface roughness including vegetation is generally taken into account by mean of roughness parameters in the modified law of the wall. However, the turbulence structure within the canopy region cannot be captured with this method, another method which applies source/sink terms to model plant drag can be used. These models have been developed and tested intensively but with a simple surface geometry. This paper aims to compare the use of roughness parameter, and additional source/sink terms in modeling the effect of plant drag on wind flow over a complex vegetated surface. The RNG k-ε turbulence model with the non-equilibrium wall function was tested with both cases. In addition, the k-ω turbulence model, which is claimed to be computationally stable, was also investigated with the source/sink terms. All numerical results were compared to the experimental results obtained at the study site Mason Bay, Stewart Island, New Zealand. In the near-surface region, it is found that the results obtained by using the source/sink term are more accurate than those using roughness parameters. The k-ω turbulence model with source/sink term is more appropriate as it is more accurate and more computationally stable than the RNG k-ε turbulence model. At higher region, there is no significant difference amongst the results obtained from all simulations.
Abstract: Deep cold rolling (DCR) and low plasticity burnishing (LPB) process are cold working processes, which easily produce a smooth and work-hardened surface by plastic deformation of surface irregularities. The present study focuses on the surface roughness and surface hardness aspects of AISI 4140 work material, using fractional factorial design of experiments. The assessment of the surface integrity aspects on work material was done, in order to identify the predominant factors amongst the selected parameters. They were then categorized in order of significance followed by setting the levels of the factors for minimizing surface roughness and/or maximizing surface hardness. In the present work, the influence of main process parameters (force, feed rate, number of tool passes/overruns, initial roughness of the work piece, ball material, ball diameter and lubricant used) on the surface roughness and the hardness of AISI 4140 steel were studied for both LPB and DCR process and the results are compared. It was observed that by using LPB process surface hardness has been improved by 167% and in DCR process surface hardness has been improved by 442%. It was also found that the force, ball diameter, number of tool passes and initial roughness of the workpiece are the most pronounced parameters, which has a significant effect on the work piece-s surface during deep cold rolling and low plasticity burnishing process.
Abstract: An area-integrating method that uses the technique of total integrated light scatter for evaluating the root mean square height of the surface Sq has been presented in the paper. It is based on the measurement of the scatter power using a flat photodiode integrator rather than an optical sphere or a hemisphere. By this means, one can obtain much less expensive and smaller instruments than traditional ones. Thanks to this, they could find their application for surface control purposes, particularly in small and medium size enterprises. A description of the functioning of the measuring unit as well as the impact caused by different factors on its properties is presented first. Next, results of measurements of the Sq values performed for optical, silicon and metal samples have been shown. It has been also proven that they are in a good agreement with the results obtained using the Ulbricht sphere instrument.
Abstract: Surface metrology with image processing is a challenging task having wide applications in industry. Surface roughness can be evaluated using texture classification approach. Important aspect here is appropriate selection of features that characterize the surface. We propose an effective combination of features for multi-scale and multi-directional analysis of engineering surfaces. The features include standard deviation, kurtosis and the Canny edge detector. We apply the method by analyzing the surfaces with Discrete Wavelet Transform (DWT) and Dual-Tree Complex Wavelet Transform (DT-CWT). We used Canberra distance metric for similarity comparison between the surface classes. Our database includes the surface textures manufactured by three machining processes namely Milling, Casting and Shaping. The comparative study shows that DT-CWT outperforms DWT giving correct classification performance of 91.27% with Canberra distance metric.
Abstract: A mathematical model of the surface roughness
has been developed by using response surface methodology
(RSM) in grinding of AISI D2 cold work tool steels. Analysis
of variance (ANOVA) was used to check the validity of the
model. Low and high value for work speed and feed rate are
decided from design of experiment. The influences of all
machining parameters on surface roughness have been
analyzed based on the developed mathematical model. The
developed prediction equation shows that both the feed rate
and work speed are the most important factor that influences
the surface roughness. The surface roughness was found to be
the lowers with the used of low feed rate and low work speed.
Accuracy of the best model was proved with the testing data.
Abstract: In recent years, scanning probe atomic force
microscopy SPM AFM has gained acceptance over a wide spectrum
of research and science applications. Most fields focuses on physical,
chemical, biological while less attention is devoted to manufacturing
and machining aspects. The purpose of the current study is to assess
the possible implementation of the SPM AFM features and its
NanoScope software in general machining applications with special
attention to the tribological aspects of cutting tool. The surface
morphology of coated and uncoated as-received carbide inserts is
examined, analyzed, and characterized through the determination of
the appropriate scanning setting, the suitable data type imaging
techniques and the most representative data analysis parameters
using the MultiMode SPM AFM in contact mode. The NanoScope
operating software is used to capture realtime three data types
images: “Height", “Deflection" and “Friction". Three scan sizes are
independently performed: 2, 6, and 12 μm with a 2.5 μm vertical
range (Z). Offline mode analysis includes the determination of three
functional topographical parameters: surface “Roughness", power
spectral density “PSD" and “Section". The 12 μm scan size in
association with “Height" imaging is found efficient to capture every
tiny features and tribological aspects of the examined surface. Also,
“Friction" analysis is found to produce a comprehensive explanation
about the lateral characteristics of the scanned surface. Configuration
of many surface defects and drawbacks has been precisely detected
and analyzed.
Abstract: Heat source addition to the axisymmetric supersonic
inlet may improve the performance parameters, which will increase
the inlet efficiency. In this investigation the heat has been added to
the flow field at some distance ahead of an axisymmetric inlet by
adding an imaginary thermal source upstream of cowl lip. The effect
of heat addition on the drag coefficient, mass flow rate and the
overall efficiency of the inlet have been investigated. The results
show that heat addition causes flow separation, hence to prevent this
phenomena, roughness has been added on the spike surface.
However, heat addition reduces the drag coefficient and the inlet
mass flow rate considerably. Furthermore, the effects of position,
size, and shape on the inlet performance were studied. It is found that
the thermal source deflects the flow streamlines. By improper
location of the thermal source, the optimum condition has been
obtained. For the optimum condition, the drag coefficient is
considerably reduced and the inlet mass flow rate and its efficiency
have been increased slightly. The optimum shape of the heat source
is obtained too.
Abstract: Evaluation of contact pressure, surface and
subsurface contact stresses are essential to know the functional
response of surface coatings and the contact behavior mainly depends
on surface roughness, material property, thickness of layer and the
manner of loading. Contact parameter evaluation of real rough
surface contacts mostly relies on statistical single asperity contact
approaches. In this work, a three dimensional layered solid rough
surface in contact with a rigid flat is modeled and analyzed using
finite element method. The rough surface of layered solid is
generated by FFT approach. The generated rough surface is exported
to a finite element method based ANSYS package through which the
bottom up solid modeling is employed to create a deformable solid
model with a layered solid rough surface on top. The discretization
and contact analysis are carried by using the same ANSYS package.
The elastic, elastoplastic and plastic deformations are continuous in
the present finite element method unlike many other contact models.
The Young-s modulus to yield strength ratio of layer is varied in the
present work to observe the contact parameters effect while keeping
the surface roughness and substrate material properties as constant.
The contacting asperities attain elastic, elastoplastic and plastic states
with their continuity and asperity interaction phenomena is inherently
included. The resultant contact parameters show that neighboring
asperity interaction and the Young-s modulus to yield strength ratio
of layer influence the bulk deformation consequently affect the
interface strength.
Abstract: The standard approach to image reconstruction is to stabilize the problem by including an edge-preserving roughness penalty in addition to faithfulness to the data. However, this methodology produces noisy object boundaries and creates a staircase effect. The existing attempts to favor the formation of smooth contour lines take the edge field explicitly into account; they either are computationally expensive or produce disappointing results. In this paper, we propose to incorporate the smoothness of the edge field in an implicit way by means of an additional penalty term defined in the wavelet domain. We also derive an efficient half-quadratic algorithm to solve the resulting optimization problem, including the case when the data fidelity term is non-quadratic and the cost function is nonconvex. Numerical experiments show that our technique preserves edge sharpness while smoothing contour lines; it produces visually pleasing reconstructions which are quantitatively better than those obtained without wavelet-domain constraints.
Abstract: Psoriasis is a widespread skin disease affecting up to 2% population with plaque psoriasis accounting to about 80%. It can be identified as a red lesion and for the higher severity the lesion is usually covered with rough scale. Psoriasis Area Severity Index (PASI) scoring is the gold standard method for measuring psoriasis severity. Scaliness is one of PASI parameter that needs to be quantified in PASI scoring. Surface roughness of lesion can be used as a scaliness feature, since existing scale on lesion surface makes the lesion rougher. The dermatologist usually assesses the severity through their tactile sense, therefore direct contact between doctor and patient is required. The problem is the doctor may not assess the lesion objectively. In this paper, a digital image analysis technique is developed to objectively determine the scaliness of the psoriasis lesion and provide the PASI scaliness score. Psoriasis lesion is modelled by a rough surface. The rough surface is created by superimposing a smooth average (curve) surface with a triangular waveform. For roughness determination, a polynomial surface fitting is used to estimate average surface followed by a subtraction between rough and average surface to give elevation surface (surface deviations). Roughness index is calculated by using average roughness equation to the height map matrix. The roughness algorithm has been tested to 444 lesion models. From roughness validation result, only 6 models can not be accepted (percentage error is greater than 10%). These errors occur due the scanned image quality. Roughness algorithm is validated for roughness measurement on abrasive papers at flat surface. The Pearson-s correlation coefficient of grade value (G) of abrasive paper and Ra is -0.9488, its shows there is a strong relation between G and Ra. The algorithm needs to be improved by surface filtering, especially to overcome a problem with noisy data.
Abstract: The contribution is dealing with the influence of high speed parameters on the quality of machined surface. In general the principle of high speed cutting lies in achieving faster machine times with concurrent increase in accuracy and quality of the machined areas in largely irregular, mathematically hard to define shapes. High speed machining is a highly effective method of machining with the following goals: increasing of machining productivity, increasing of quality of the machined surface, improving of machining economy, improving of ecological aspects of machining. This article is based on an experiment performed by the Department of Machining and Assembly of the Faculty of Mechanical Engineering of VŠBTechnical University of Ostrava.
Abstract: The machining of Carbon Fiber Reinforced Plastics
has come to constitute a significant challenge for many fields of
industry. The resulting surface finish of machined parts is of primary
concern for several reasons, including contact quality and impact on
the assembly. Therefore, the characterization and prediction of
roughness based on machining parameters are crucial for costeffective
operations. In this study, a PCD tool comprised of two
straight flutes was used to trim 32-ply carbon fiber laminates in a bid
to analyze the effects of the feed rate and the cutting speed on the
surface roughness. The results show that while the speed has but a
slight impact on the surface finish, the feed rate for its part affects it
strongly. A detailed study was also conducted on the effect of fiber
orientation on surface roughness, for quasi-isotropic laminates used
in aerospace. The resulting roughness profiles for the four-ply
orientation lay-up were compared, and it was found that fiber angle is
a critical parameter relating to surface roughness. One of the four
orientations studied led to very poor surface finishes, and
characteristic roughness profiles were identified and found to only
relate to the ply orientations of multilayer carbon fiber laminates.
Abstract: A numerical simulation of micro Poiseuille flow has
performed for rarefied and compressible flow at slip flow regimes.
The wall roughness is simulated in two cases with triangular
microelements and random micro peaks distributed on wall surfaces
to study the effects of roughness shape and distribution on flow field.
Two values of Mach and Knudsen numbers have used to investigate
the effects of rarefaction as well as compressibility. The numerical
results have also checked with available theoretical and experimental
relations and good agreements has achieved. High influence of
roughness shape can be seen for both compressible and
incompressible rarefied flows. In addition it is found that rarefaction
has more significant effect on flow field in microchannels with
higher relative roughness. It is also found that compressibility has
more significant effects on Poiseuille number when relative
roughness increases.
Abstract: The stochastic nature of tool life using conventional discrete-wear data from experimental tests usually exists due to many individual and interacting parameters. It is a common practice in batch production to continually use the same tool to machine different parts, using disparate machining parameters. In such an environment, the optimal points at which tools have to be changed, while achieving minimum production cost and maximum production rate within the surface roughness specifications, have not been adequately studied. In the current study, two relevant aspects are investigated using coated and uncoated inserts in turning operations: (i) the accuracy of using machinability information, from fixed parameters testing procedures, when variable parameters situations are emerged, and (ii) the credibility of tool life machinability data from prior discrete testing procedures in a non-stop machining. A novel technique is proposed and verified to normalize the conventional fixed parameters machinability data to suit the cases when parameters have to be changed for the same tool. Also, an experimental investigation has been established to evaluate the error in the tool life assessment when machinability from discrete testing procedures is employed in uninterrupted practical machining.
Abstract: In this paper an attempt has been made to correlate the usefulness of electrodes made through powder metallurgy (PM) in comparison with conventional copper electrode during electric discharge machining. Experimental results are presented on electric discharge machining of AISI D2 steel in kerosene with copper tungsten (30% Cu and 70% W) tool electrode made through powder metallurgy (PM) technique and Cu electrode. An L18 (21 37) orthogonal array of Taguchi methodology was used to identify the effect of process input factors (viz. current, duty cycle and flushing pressure) on the output factors {viz. material removal rate (MRR) and surface roughness (SR)}. It was found that CuW electrode (made through PM) gives high surface finish where as the Cu electrode is better for higher material removal rate.
Abstract: In this paper, the experimental design of using the
Taguchi method is employed to optimize the processing parameters in
the plasma arc surface hardening process. The processing parameters
evaluated are arc current, scanning velocity and carbon content of
steel. In addition, other significant effects such as the relation between
processing parameters are also investigated. An orthogonal array,
signal-to-noise (S/N) ratio and analysis of variance (ANOVA) are
employed to investigate the effects of these processing parameters.
Through this study, not only the hardened depth increased and surface
roughness improved, but also the parameters that significantly affect
the hardening performance are identified. Experimental results are
provided to verify the effectiveness of this approach.
Abstract: The morphological parameter of a thin film surface
can be characterized by power spectral density (PSD) functions
which provides a better description to the topography than the RMS
roughness and imparts several useful information of the surface
including fractal and superstructure contributions. Through the
present study Nanoparticle copper/carbon composite films were
prepared by co-deposition of RF-Sputtering and RF-PECVD method
from acetylene gas and copper target. Surface morphology of thin
films is characterized by using atomic force microscopy (AFM). The
Carbon content of our films was obtained by Rutherford Back
Scattering (RBS) and it varied from .4% to 78%. The power values of
power spectral density (PSD) for the AFM data were determined by
the fast Fourier transform (FFT) algorithms. We investigate the effect
of carbon on the roughness of thin films surface. Using such
information, roughness contributions of the surface have been
successfully extracted.