In this paper, an experimental surface roughness analysis in milling of tungsten carbide using a monolithic torus cubic boron nitride (CBN) tool is presented. The tungsten carbide was received using direct laser deposition technology (DLD). The depth of cut (ap), feed per tooth (fz) and tool wear (VBc) influence on surface roughness parameters (Ra, Rz) were investigated. The cutting forces and accelerations of vibrations were measured in order to estimate their quantitative influence on Ra and Rz parameters. The surface roughness analysis, from the point of view of milling dynamics was carried out. The dominative factor in the research was not feed per tooth fz (according to a theoretical model) but dynamical phenomena and feed per revolution f connected with them.
The paper presents the results of investigations of the growth of protective coating on the surface of ductile iron casting during the hot-dip
galvanizing treatment. Ductile iron of the EN-GJS-600-3 grade was melted and two moulds made by different technologies were poured to
obtain castings with different surface roughness parameters. After the determination of surface roughness, the hot-dip galvanizing
treatment was carried out. Based on the results of investigations, the effect of casting surface roughness on the kinetics of the zinc coating
growth was evaluated. It was found that surface roughness exerts an important effect on the thickness of produced zinc coating
Surface roughness parameter prediction and evaluation are important factors in determining the satisfactory performance of machined surfaces in many fields. The recent trend towards the measurement and evaluation of surface roughness has led to renewed interest in the use of newly developed non-contact sensors. In the present work, an attempt has been made to measure the surface roughness parameter of different machined surfaces using a high sensitivity capacitive sensor. A capacitive response model is proposed to predict theoretical average capacitive surface roughness and compare it with the capacitive sensor measurement results. The measurements were carried out for 18 specimens using the proposed capacitive-sensor-based non-contact measurement setup. The results show that surface roughness values measured using a sensor well agree with the model output. For ground and milled surfaces, the correlation coefficients obtained are high, while for the surfaces generated by shaping, the correlation coefficient is low. It is observed that the sensor can effectively assess the fine and moderate rough-machined surfaces compared to rough surfaces generated by a shaping process. Furthermore, a linear regression model is proposed to predict the surface roughness from the measured average capacitive roughness. It can be further used in on-machine measurement, on-line monitoring and control of surface roughness in the machine tool environment.
The prediction of machined surface parameters is an important factor in machining centre development. There is a great need to elaborate a method for on-line surface roughness estimation [1-7]. Among various measurement techniques, optical methods are considered suitable for in-process measurement of machined surface roughness. These techniques are non-contact, fast, flexible and tree-dimensional in nature.
The optical method suggested in this paper is based on the vision system created to acquire an image of the machined surface during the cutting process. The acquired image is analyzed to correlate its parameters with surface parameters. In the application of machined surface image analysis, the wavelet methods were introduced. A digital image of a machined surface was described using the one-dimensional Digital Wavelet Transform with the basic wavelet as Coiflet. The statistical description of wavelet components made it possible to develop the quality measure and correlate it with surface roughness [8-11].
For an estimation of surface roughness a neural network estimator was applied [12-16]. The estimator was built to work in a recurrent way. The current value of the Ra estimation and the measured change in surface image features were used for forecasting the surface roughness Ra parameter. The results of the analysis confirmed the usability of the application of the proposed method in systems for surface roughness monitoring.
A numerical solution is presented to investigate the influence of the geometry and the amplitude of the transverse ridge on the characteristics of elastohydrodynamic lubrication for point contact problem under steady state condition. Several shapes of ridges with different amplitudes are used in the stationary case, such as flattop ridge, cosine wave ridge and sharp ridge of triangular shape. Results of film thickness and pressure distributions of the aforementioned ridge feature are presented at different locations through an elastohydrodynamically lubricated contact zone for different amplitude of the ridge. Simulations were performed using the Newton-Raphson iteration technique to solve the Reynolds equation. The numerical results reveal that, to predict optimum solution for lubricated contact problem with artificial surface roughness, the geometrical characteristics of the ridge should have profiles with smooth transitions such as those of a cosine wave shape with relatively low amplitude to reduce pressure spike and therefore cause the reduction in the film thickness. The position of the location of the ridge across the contact zone and the amplitude of the ridge play an important role in the formation of lubricant film thickness and therefore determine the pressure distribution through the contact zone.
In this paper, the authors present surface roughness profile assessment using continuous wavelet transform (CWT). Roughness profiles after turning and rough and finish belt grinding of hardened (62HRC) AISI 52100 steel are analyzed. Both Morlet and “Mexican hat” analyzing wavelets are used for the assessment of extrema and frequency distribution. The results of the CWT as a function of profile and momentary wavelet length are presented. It is concluded that CWT can be useful for the analysis of the roughness profiles generated by cutting and abrasive machining processes.
This paper explores the parametric appraisal and machining performance optimization during drilling of polymer nanocomposites reinforced by graphene oxide/carbon fiber. The consequences of drilling parameters like cutting velocity, feed, and weight % of graphene oxide on machining responses, namely surface roughness, thrust force, torque, delamination (In/Out) has been investigated. An integrated approach of a Combined Quality Loss concept, Weighted Principal Component Analysis (WPCA), and Taguchi theory is proposed for the evaluation of drilling efficiency. Response surface methodology was employed for drilling of samples using the titanium aluminum nitride tool. WPCA is used for aggregation of multi-response into a single objective function. Analysis of variance reveals that cutting velocity is the most influential factor trailed by feed and weight % of graphene oxide. The proposed approach predicts the outcomes of the developed model for an optimal set of parameters. It has been validated by a confirmatory test, which shows a satisfactory agreement with the actual data. The lower feed plays a vital role in surface finishing. At lower feed, the development of the defect and cracks are found less with an improved surface finish. The proposed module demonstrates the feasibility of controlling quality and productivity factors.
Titanium alloy (Ti-6Al-4V) has been extensively used in aircraft turbine-engine components, aircraft structural components, aerospace fasteners, high performance automotive parts, marine applications, medical devices and sports equipment. However, wide-spread use of this alloy has limits because of difficulty to machine it. One of the major difficulties found during machining is development of poor quality of surface in the form of higher surface roughness. The present investigation has been concentrated on studying the effects of cutting parameters of cutting speed, feed rate and depth of cut on surface roughness of the product during turning of titanium alloy. Box-Behnken experimental design was used to collect data for surface roughness. ANOVA was used to determine the significance of the cutting parameters. The model equation is also formulated to predict surface roughness. Optimal values of cutting parameters were determined through response surface methodology. A 100% desirability level in the turning process for economy was indicated by the optimized model. Also, the predicted values that were obtained through regression equation were found to be in close agreement to the experimental values.
Titania dioxide (TiO2) layers were synthesized via the acid-catalysed sol-gel route using titania (IV) ethoxide, and then annealed at temperatures varying in the range of 150–700 °C. The research concerned the effect of annealing temperature on the structure of TiO2 layers, their surface morphology, and their optical properties. Further, X-ray diffractometry, and Raman spectroscopy were used to determine the structure of TiO2 layers. Scanning electron and atomic force microscopy were used to study the surface morphology of TiO2 layers. Transmittance, reflectance, absorption edge, and optical homogeneity were investigated by UV-VIS spectrophotometry, while the refractive index and thicknesses of TiO2 layers were measured using a monochromatic ellipsometer. Chromatic dispersion characteristics of the complex refractive index were determined using spectroscopic ellipsometry. Structural studies have shown that the TiO2 layers annealed at temperatures up to 300 °C are amorphous, while those annealed at temperatures exceeding 300 °C are polycrystalline containing only anatase nanocrystals with sizes increasing from 6 to 20 nm with the increase of the annealing temperature. Investigations on the surface morphology of TiO2 layers have shown that the surface roughness increases with the increase in annealing temperature. Spectrophotometric investigations have shown that TiO2 layers are homogeneous and the width of the indirect optical band gap varies with annealing temperature from 3.53 eV to 3.73 eV.
The article presents the results of research on the finishing of M63 Z4 brass by vibratory machining. Brass alloy was used for the research due to the common use of ammunition elements, cartridge case and good cold forming properties on the construction. Until now, the authors have not met with the results of research to determine the impact of abrasive pastes in container processing. It was found that the additive for container abrasive treatment of abrasive paste causes larger mass losses and faster surface smoothing effects. The treatment was carried out in two stages: in the first stage, the workpieces were deburred and then polished. Considerations were given to the impact of mass of workpieces, machining time and its type on mass loss and changes in the geometric structure of the surface. The surface roughness of machining samples was measured with the Talysurf CCI Lite optical profiler. The suggestions for future research may be to carry out tests using abrasive pastes with a larger granulation of abrasive grains, and to carry out tests for longer processing times and to determine the time after which the parameters of SGP change is unnoticeable.
This article proposes these of vibratory machining to Ti-6Al-4V titanium alloy as finishing treatment. Titanium alloy was used in the aerospace industry, military, metallurgical, automotive and medical processes, extreme sports and other. The three-level three-factor Box-Behnken experiment examined the influence of machining time of vibratory machining, the type of mass finishing media used and the initial state of the surface layer on the mass loss, geometric structure of the surface, micro hardness and the optimal process parameters were determined. Considerations were given the surfaces after milling, after cutting with a band saw and after the sanding process. The experiment used three types of mass finishing media: polyester, porcelain and metal. Duration of vibratory machining treatment was assumed to be 20, 40, 60 minutes. The form profiles before and after vibratory machining were determined with the Talysurf CCI Lite - Taylor Hobson optical profiler. Future tests should concern research to carry out tests using abrasive pastes with a larger granulation of abrasive grains, to carry out tests for longer processing times and to determine the time after which the parameters of geometrical structure of the surface change is unnoticeable.
We present a prototype of a simple, low-cost setup for a fast scatterometric surface texture measurements. We used a total integrated scatter method (TIS) with a semiconductor laser (λ = 638 nm) and a Si photodiode. Using our setup, we estimated the roughness parameters Rq for two reference surfaces (Al mirrors with flatness λ/10) and seven equal steel plates to compare. The setup is easily adaptable for a fast, preliminary manufacturing quality control. We show is possible to construct a low-cost measurement system with nanometric precision.