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: The present study focused on the investigation of the
effects of roughness elements on heat transfer during natural
convection in a rectangular cavity using numerical technique.
Roughness elements were introduced on the bottom hot wall with a
normalized amplitude (A*/H) of 0.1. Thermal and hydrodynamic
behaviors were studied using computational method based on Lattice
Boltzmann method (LBM). Numerical studies were performed for a
laminar flow in the range of Rayleigh number (Ra) from 103 to 106
for a rectangular cavity of aspect ratio (L/H) 2.0 with a fluid of
Prandtl number (Pr) 1.0. The presence of the sinusoidal roughness
elements caused a minimum to maximum decrease in the heat
transfer as 7% to 17% respectively compared to smooth enclosure.
The results are presented for mean Nusselt number (Nu), isotherms
and streamlines.
Abstract: Wire Electric Discharge Machining (WEDM) is
thermal machining process capable of machining very hard
electrically conductive material irrespective of their hardness.
WEDM is being widely used to machine micro scale parts with the
high dimensional accuracy and surface finish. The objective of this
paper is to optimize the process parameters of wire EDM to fabricate
the micro channels and to calculate the surface finish and material
removal rate of micro channels fabricated using wire EDM. The
material used is aluminum 6061 alloy. The experiments were
performed using CNC wire cut electric discharge machine. The effect
of various parameters of WEDM like pulse on time (TON) with the
levels (100, 150, 200), pulse off time (TOFF) with the levels (25, 35,
45) and current (IP) with the levels (105, 110, 115) were investigated
to study the effect on output parameter i.e. Surface Roughness and
Material Removal Rate (MRR). Each experiment was conducted
under different conditions of pulse on time, pulse off time and peak
current. For material removal rate, TON and Ip
were the most significant process parameter. MRR increases with the increase in
TON and Ip and decreases with the increase in TOFF. For surface
roughness, TON and Ip have the maximum effect and TOFF was found
out to be less effective.
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: The present work analyses different parameters of end
milling to minimize the surface roughness for AISI D2 steel. D2 Steel
is generally used for stamping or forming dies, punches, forming
rolls, knives, slitters, shear blades, tools, scrap choppers, tyre
shredders etc. Surface roughness is one of the main indices that
determines the quality of machined products and is influenced by
various cutting parameters. In machining operations, achieving
desired surface quality by optimization of machining parameters, is a
challenging job. In case of mating components the surface roughness
become more essential and is influenced by the cutting parameters,
because, these quality structures are highly correlated and are
expected to be influenced directly or indirectly by the direct effect of
process parameters or their interactive effects (i.e. on process
environment). In this work, the effects of selected process parameters
on surface roughness and subsequent setting of parameters with the
levels have been accomplished by Taguchi’s parameter design
approach. The experiments have been performed as per the
combination of levels of different process parameters suggested by
L9 orthogonal array. Experimental investigation of the end milling of
AISI D2 steel with carbide tool by varying feed, speed and depth of
cut and the surface roughness has been measured using surface
roughness tester. Analyses of variance have been performed for mean
and signal-to-noise ratio to estimate the contribution of the different
process parameters on the process.
Abstract: Polymer-like organic thin films were deposited on both
aluminum alloy type 6061 and glass substrates at room temperature by
Plasma Enhanced Chemical Vapor Deposition (PECVD) methodusing
benzene and hexamethyldisiloxane (HMDSO) as precursor materials.
The surface and physical properties of plasma-polymerized organic
thin films were investigated at different r.f. powers. The effects of
benzene/argon ratio on the properties of plasma polymerized benzene
films were also investigated. It is found that using benzene alone
results in a non-coherent and non-adherent powdery deposited
material. The chemical structure and surface properties of the asgrown
plasma polymerized thin films were analyzed on glass
substrates with FTIR and contact angle measurements. FTIR spectra
of benzene deposited film indicated that the benzene rings are
preserved when increasing benzene ratio and/or decreasing r.f.
powers. FTIR spectra of HMDSO deposited films indicated an
increase of the hydrogen concentration and a decrease of the oxygen
concentration with the increase of r.f. power. The contact angle (θ) of
the films prepared from benzene was found to increase by about 43%
as benzene ratio increases from 10% to 20%. θ was then found to
decrease to the original value (51°) when the benzene ratio increases
to 100%. The contact angle, θ, for both benzene and HMDSO
deposited films were found to increase with r.f. power. This signifies
that the plasma polymerized organic films have substantially low
surface energy as the r.f power increases. The corrosion resistance of
aluminum alloy substrate both bare and covered with plasma
polymerized thin films was carried out by potentiodynamic
polarization measurements in standard 3.5 wt. % NaCl solution at
room temperature. The results indicate that the benzene and HMDSO
deposited films are suitable for protection of the aluminum substrate
against corrosion. The changes in the processing parameters seem to
have a strong influence on the film protective ability. Surface
roughness of films deposited on aluminum alloy substrate was
investigated using scanning electron microscopy (SEM). The SEM
images indicate that the surface roughness of benzene deposited films
increase with decreasing the benzene ratio. SEM images of benzene
and HMDSO deposited films indicate that the surface roughness
decreases with increasing r.f. power. Studying the above parameters
indicate that the films produced are suitable for specific practical
applications.
Abstract: The present paper is an experimental investigation of
roughness effects on nucleate pool boiling of refrigerant R113 on
horizontal circular copper surfaces. The copper samples were treated
by different sand paper grit sizes to achieve different surface
roughness. The average surface roughness of the four samples was
0.901, 0.735, 0.65, and 0.09, respectively. The experiments were
performed in the heat flux range of 8 to 200kW/m2. The heat transfer
coefficient was calculated by measuring wall superheat of the
samples and the input heat flux. The results show significant
improvement of heat transfer coefficient as the surface roughness is
increased. It is found that the heat transfer coefficient of the sample
with Ra=0.901 is 3.4, 10.5, and 38.5% higher in comparison with
surfaces with Ra of 0.735, 0.65, and 0.09 at heat flux of 170 kW/m2.
Moreover, the results are compared with literature data and the well
known Cooper correlation.
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: 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: 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: Heating is inevitable in any bearing operation. This
leads to not only the thinning of the lubricant but also could lead to a
thermal deformation of the bearing. The present work is an attempt to
analyze the influence of thermal deformation on the thermohydrodynamic
lubrication of infinitely long tilted pad slider rough
bearings. As a consequence of heating the slider is deformed and is
assumed to take a parabolic shape. Also the asperities expand leading
to smaller effective film thickness. Two different types of surface
roughness are considered: longitudinal roughness and transverse
roughness. Christensen-s stochastic approach is used to derive the
Reynolds-type equations. Density and viscosity are considered to be
temperature dependent. The modified Reynolds equation, momentum
equation, continuity equation and energy equation are decoupled and
solved using finite difference method to yield various bearing
characteristics. From the numerical simulations it is observed that the
performance of the bearing is significantly affected by the thermal
distortion of the slider and asperities and even the parallel sliders
seem to carry some load.
Abstract: A novel nanofinishing process using improved ball
end magnetorheological (MR) finishing tool was developed for finishing of flat as well as 3D surfaces of ferromagnetic and non ferromagnetic workpieces. In this process a magnetically controlled
ball end of smart MR polishing fluid is generated at the tip surface of
the tool which is used as a finishing medium and it is guided to
follow the surface to be finished through computer controlled 3-axes
motion controller. The experiments were performed on ferromagnetic
workpiece surface in the developed MR finishing setup to study the effect of finishing time on final surface roughness. The performance
of present finishing process on final finished surface roughness was studied. The surface morphology was observed under scanning
electron microscopy and atomic force microscope. The final surface finish was obtained as low as 19.7 nm from the initial surface
roughness of 142.9 nm. The outcome of newly developed finishing process can be found useful in its applications in aerospace,
automotive, dies and molds manufacturing industries, semiconductor and optics machining etc.
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.