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Number of results: 382
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Abstract

Artificial neural network (ANN), a Computational tool that is frequently applied in the modeling and simulation of manufacturing processes. The emerging forming technique of sheet metal which is typically called single point incremental forming (SPIF) comes into the map and the research interest towards its technological parameters. The surface quality of the end product is a major issue in SPIF, which is more critical with the hard metals. The part of the brass metal is demanded in many industrial uses because of its high load-carrying capacity and its wear resistance property. Considering the industrial interest and demand of the brass metal products, the present study is done with the SPIF experiment on calamine brass Cu67Zn33 followed by an ANN analysis for predicting the absolute surface roughness. The modeling result shows a close agreement with the measured data. The minimum and maximum errors are found in experiment 3 and experiment 7 respectively. The error of predicted roughness is found in the range of –30.87 to 20.23 and the overall coefficient of performance of ANN modeling is 0.947 which is quite acceptable.
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Authors and Affiliations

Manish Oraon
1
Vinay Sharma
1

  1. Birla Institute of Technology, Faculty of Production Engineering, India
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Abstract

This paper presents an approach based on NURBS (non-uniform rational B-splines) to achieve a seismic response surface (SRS) from a group of points obtained by using an analytical model of RC joints. NURBS based on the genetic algorithm is an important mathematical tool and consists of generalizations of Bezier curves and surfaces and B-splines. Generally, the accuracy of the design process of joints depends on the number of control points that are captured in the results of experimental research on real specimens. The values obtained from the specimens are the best tools to use in seismic analysis, though more expensive when compared to values simulated by SRSs. The SRS proposed in this paper can be applied to obtain surfaces that show site effect results on destructions of beam-column joint, taking into account different site conditions for a specific earthquake. The efficiency of this approach is demonstrated by the retrieval of simulated-versus-analytical results.

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Authors and Affiliations

R. Tabatabaei Mirhosseini
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Abstract

In a dynamic machining process, distortion in surface irregularity is a very complex phenomenon. Surface irregularities form a periodic representation of the tool profile with various kinds of disturbance in a broad range of changes in the height and length of the profile. To discern these irregularity disturbances, interactions of the tool in the form of changes perpendicular and parallel relative to the workpiece were analyzed and simulated. The individual kinds of displacement of the tool relative to the workpiece introduce distortions in the changes of height and length. These changes are weakly represented in standard height and length irregularity parameters and their discernment has been found through amplitude-frequency functions.

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Authors and Affiliations

Adam Boryczko
Wojciech Rytlewski
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Abstract

This paper presents a comprehensive methodology for measuring and characterizing the surface topographies on machined steel parts produced by precision machining operations. The performed case studies concern a wide spectrum of topographic features of surfaces with different geometrical structures but the same values of the arithmetic mean height Sa. The tested machining operations included hard turning operations performed with CBN tools, grinding operations with Al2O3 ceramic and CBN wheels and superfinish using ceramic stones. As a result, several characteristic surface textures with the Sa roughness parameter value of about 0.2 μm were thoroughly characterized and compared regarding their potential functional capabilities. Apart from the standard 2D and 3D roughness parameters, the fractal, motif and frequency parameters were taken in the consideration.

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Authors and Affiliations

Wit Grzesik
Krzysztof Żak
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Abstract

A method of manufacturing hydrogel coatings designed to increase the hydrophilicity of polyurethanes (PU) is presented. Coatings were obtained from polyvinylpyrrolidone (PVP) by free radical polymerisation. The authors proposed a mechanism of a two-step grafting - crosslinking process and investigated the influence of reagent concentration on the coating’s physical properties - hydrogel ratio (HG) and equilibrium swelling ratio (ESR). A surface analysis of freeze-dried coatings using scanning electron microscopy (SEM) showed a highly porous structure. The presented technology can be used to produce biocompatible surfaces with limited protein and cell adhesive properties and can be applied in fabrication of number of biomedical devices, e.g. catheters, vascular grafts and heart prosthesis.

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Authors and Affiliations

Tomasz Ciach
Beata Butruk
Maciej Trzaskowski
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Abstract

The use of surface analysis to investigate brake elements shows how a pair in contact works and wears out during regular operation. The main purpose of this paper is to describe the asperities from initial state to a moment when further use of the drum and shoe is not possible. Between exchange of vital brake elements a truck with total mass exceeding 3.5 tons can cover as many as 300 000 kilometres. Use of brakes during the first 1000 kilometres after maintenance should be rather gentle with possibly intensive use of engine brake installed in the truck itself, because if this rule is not adhered to it may lead to a significant decrease of the braking force and on the surface of the pair in contact a layer will appear that is not possible to wear off and that will make it impossible to stop a truck using brakes. In that condition the shoe should be immediately replaced and the drum should be remachined (by turning) to a repair dimension. In the paper the condition and analysis of a surface after different course of exploitation was presented.
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Authors and Affiliations

Michał Wieczorowski
Robert Mrozek
Paweł Andrałojć
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Abstract

Combining surface measurement data from individual measurements of surface fragments is an issue that has been recognized for flat surfaces. The connection takes place on the principle of making ‘overlap’ measurements according to a specific measurement strategy, and then the algorithm synthesizes the measurement data for the common part (data fusion). This paper presents a method of combining partial data into one larger set using image processing methods. The purpose of the analysis is to combine surface data of a more complex shape in terms of surface roughness and waviness. A successful attempt was made to combine surface measurement data located on a cylindrical surface – convex surface. A rotated table was designed and used for surface data acquisition. The datasets were acquired with the use of CCI 6000 (366 μm – 366 μm) with the assumed overlapping of at least 20%. The measurement datasets were first pre-processed: filling in non-measured points, levelling and form re- moving were applied. For such processed datasets, the common part was identified (data registration) and then the data fusion was performed. An example of stitching the surface datasets shows usefulness of the presented methodology.

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Authors and Affiliations

Anna Zawada-Tomkiewicz
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Abstract

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.

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Authors and Affiliations

D. Kucharski
H. Zdunek
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Abstract

Flap peening (FP) is a cold working technique used to apply a compressive force using small shots, this will lead to enhance the surface properties that it can sustain for long life during working conditions. In this study, several aircraft aluminum alloys materials namely; 2219 T6, 2024 T6, 7075T6, and 6061 T6 were flap peened under different rotational speeds. The effect of rotational speed on the average surface roughness (Ra) and average surface micro hardness have been investigated. As seen by the Scanning Electron Microscope SEM phots that the hardness of peened layer is increased. It was found that as the flap peening speeds increase the percent change in surface roughness (Ra) increases, and the percent change in surface micro hardness decreases. The maximum increase in Ra occurs in 2219 T80 and the minimum in 6061 T6 alloys, and for hardness, it is reported that the maximum occurs in 6061 T6 and the minimum in 2019 T80 alloy.
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Authors and Affiliations

Nabeel Abu Shaban
1
ORCID: ORCID
Nabeel Alshabatat
2
Safwan Al-Qawabah
1
ORCID: ORCID

  1. Al-Zaytoonah University of Jordan, Mechanical Engineering Department, Amman, Jordan
  2. Tafila Technical University, Mechanical Engineering Department, Tafila 66110, Jordan
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Abstract

This study summarises the research efforts undertaken in iron foundry plants in which the process are mostly automated and mechanised.

The research program was limited in scope, focusing on causes of surface defects in castings products that are attributable to the

bentonite-containing sand and the mould system. One of the potential roots of surface defects is heterogeneity of sand grains, containing

lumped ball-shaped grains and irregular pellets with a layered-structure. The moisture contents of those lumped grains is different than

the moisture level required in the process, besides these grains may contain various elements and metallic compounds which, when cast

into moulds, may react with molten metals in an uncontrolled manner. As a result, surface defects are produced, such as surface blowholes,

burst penetration, sand holes, slag inclusions, pinhole porosity. This study investigated the efficiency of key sand preparation and

moulding machines and installations integrated into the casting process line. The efficiency of machines and installations is defined in

terms of quality parameters of sand mix and moulds, which are associated with the emergence of surface defects on castings.

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Authors and Affiliations

R. Wrona
E. Ziółkowski
M. Brzeziński
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Abstract

The irregularity profiles of steel samples after vapour blasting were measured. A correlation analysis of profile parameters was then carried out. As the result, the following parameters were selected: Pq, Pt, PDq, Pp/Pt and Pku. Surface profiles after vapour blasting were modeled. The modeled surfaces were correctly matched to measured surfaces in 78% of all analyzed cases. The vapour blasting experiment was then carried out using an orthogonal selective research plan. The distance between the nozzle and sample d and the pressure of feed system p were input parameters; selected surface texture coefficients were output parameters. As the result of the experiment, regression equations connecting vapour blasting process parameters p and d with selected profile parameters were obtained. Finally, 2D profiles of steel samples were forecasted for various values of vapour blasting parameters. Proper matching accuracy of modeled to measured profiles was assured in 75% of analyzed cases.
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Authors and Affiliations

Paweł Pawlus
Rafał Reizer
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Abstract

The paper presents the properties of surface oxide layers with an increased content of carbon for tribological applications. The composite surface oxide layers were produced using a two-step technology through hard anodising of the surface of an aluminium alloy, followed by thermochemical treatment of anodic oxide coatings. The surface oxide layers were subjected to tribological tests in an oil-less sliding couple with T5W plastic. The presented test results confirm the usefulness of the proposed modifications of surface oxide layers for the purpose of enhancing the operational durability of oil-less sliding couples in a reciprocating motion.

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Authors and Affiliations

Tomasz Kmita
Marek Bara
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Abstract

Measurements of dynamic surface tension were carried out in aqueous systems (water or 0.1 mM Triton X-100) comprising nanoparticles formed from chemically modified polyaldehyde dextran (PAD). The nanostructures, considered as potential drug carriers in aerosol therapy, were obtained from biocompatible polysaccharides by successive oxidation and reactive coiling in an aqueous solution. The dynamic surface tension of the samples was determined by the maximum bubble pressure (MBP) method and by the axisymmetric drop shape analysis (ADSA). Experiments with harmonic area perturbations were also carried out in order to determine surface dilatational viscoelasticity. PAD showed a remarkable surface activity. Ward-Tordai equation was used to determine the equilibrium surface tension and diffusion coefficient of PAD nanoparticles (D = 2.3×10-6 m2/s). In a mixture with Triton X-100, PAD particles showed co-adsorption and synergic effect in surface tension reduction at short times (below 10 s). Tested nanoparticles had impact on surface rheology in a mixed system with nonionic surfactant, suggesting their possible interactions with the lung surfactant system after inhalation. This preliminary investigation sets the methodological approach for further research related to the influence of inhaled PAD nanoparticles on the lung surfactant and mass transfer processes in the respiratory system.

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Authors and Affiliations

Katarzyna Jabłczyńska
Tomasz R. Sosnowski
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Abstract

The paper presents recent developments concerning the formation of surface layer in austempered ductile iron castings. It was found that the traditional methods used to change the properties of the surface layer, i.e. the effect of protective atmosphere during austenitising or shot peening, are not fully satisfactory to meet the demands of commercial applications. Therefore, new ways to shape the surface layer and the surface properties of austempered ductile iron castings are searched for, to mention only detonation spraying, carbonitriding, CVD methods, etc.

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Authors and Affiliations

D. Myszka
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Abstract

The article presents an example of finishing treatment for aluminum alloys with the use of vibration machining, with loose abrasive media in a closed tumbler. For the analysis of selected properties of the surface layer prepared flat samples of aluminum alloy PA6/2017 in the state after recrystallization. The samples in the first stage were subjected to a treatment of deburring using ceramic media. In a second step polishing process performed with a strengthening metal media. In addition, for comparative purposes was considered. only the case of metal polishing. The prepared samples were subjected to hardness tests and a tangential tensile test. As a result of finishing with vibratory machining, it was possible to remove burrs, flash, rounding sharp edges, smoothing and lightening the surface of objects made. The basic parameters of the surface geometry were obtained using the Talysurf CCI Lite - Taylor Hobson optical profiler. As a result of the tests it can be stated that the greatest reduction of surface roughness and mass loss occurs in the first minutes of the process. Mechanical tests have shown that the most advantageous high values of tensile strength and hardness are obtained with two-stage vibration treatment, - combination of deburring and polishing. Moreover the use of metal media resulted in the strengthening of the surface by pressure deburring with metal media.

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Authors and Affiliations

D. Bańkowski
S. Spadło
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Abstract

The production process of prosthetic restorations runs in two stages. In the first stage, the prosthetic foundation is produced of metal

alloys. In the second stage, a facing material is applied on the produced element. In both stages, the wettability is significantly important,

as well as the free surface energy relating to it. The quality of the obtained cast depends on the surface phenomena occurring between the

metal alloy and the material of which the casting mould is made. The performed examinations also point to a relation between the ceramics

joint and the base, depending on the wetting angle.

The aim of the presented paper was to examine influence of the composition of a Ti(C,N)-type coating on bases made of the Ni-Cr

prosthetic alloy on the wettability and the surface free energy.

The test material were disks made of the Ni-Cr alloy with the diameter of 8 mm. The disks were divided into five groups, which were

covered with Ti(C,N) coatings, with different amounts of C and N in the layer. In order to determine the surface free energy (����), the

wetting angle was measured. Two measure liquids were applied: distilled water and diiodomethane.

The obtained results of the measurements of the water-wetting angles suggest that together with the increase of the ratio of nitrogen to

carbon in the Ti(C,N) coating, the surface hydrophobicity increases as well. In all the samples, one can see a large difference between the

energy values of the polar and the apolar components. The high values of the polar components and the low values of the apolar ones make

it possible to conclude that these surfaces exhibit a greater affinity to the polar groups than to the apolar ones.

On the basis of the analysis of the surface free energy, one can state that covering the alloy with Ti(C,N)-type coatings should not decrease

the adhesion of the ceramics to the alloy, whereas TiC coatings should lead to the latter’s improvement. Due to their hydrophilicity, TiC

coatings should decrease the adhesion of bacteria to the surface and hinder the formation of a bacterial biofilm.

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Authors and Affiliations

K. Banaszek
L. Klimek
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Abstract

Paper present a thermal analysis of laser heating and remelting of EN AC-48000 (EN AC-AlSi12CuNiMg) cast alloy used mainly for

casting pistons of internal combustion engines. Laser optics were arranged such that the impingement spot size on the material was a

circular with beam radius rb changes from 7 to 1500 m. The laser surface remelting was performed under argon flow. The resulting

temperature distribution, cooling rate distribution, temperature gradients and the depth of remelting are related to the laser power density

and scanning velocity. The formation of microstructure during solidification after laser surface remelting of tested alloy was explained.

Laser treatment of alloy tests were perform by changing the three parameters: the power of the laser beam, radius and crystallization rate.

The laser surface remelting needs the selection such selection of the parameters, which leads to a significant disintegration of the structure.

This method is able to increase surface hardness, for example in layered castings used for pistons in automotive engines.

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Authors and Affiliations

J. Piątkowski
A. Grabowski
M. Czerepak
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Abstract

This study proposes a surface profile and roughness measurement system for a fibre-optic interconnect based on optical interferometry. On the principle of Fizeau interferometer, an interference fringe is formed on the fibre end-face of the fibre-optic interconnect, and the fringe pattern is analysed using the Fast Fourier transform method to reconstruct the surface profile. However, as the obtained surface profile contains some amount of tilt, a rule for estimating this tilt value is developed in this paper. The actual fibre end-face surface profile is obtained by subtracting the estimated tilt amount from the surface profile, as calculated by the Fast Fourier transform method, and the corresponding surface roughness can be determined. The proposed system is characterized by non-contact measurement, and the sample is not coated with a reflector during measurement. According to the experimental results, the difference between the roughness measurement result of an Atomic Force Microscope (AFM) and the measurement result of this system is less than 3 nm.

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Authors and Affiliations

Chern S. Lin
Shih W. Yang
Hung L. Lin
Jhih W. Li
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Abstract

The paper presents a spectral formulation of surface profile irregularity in a wideband frequency range for roughness, waviness and shape components along the measured length. A unique distribution of roughness and waviness components is proposed, according to the nature of their origination in the course of machining with tools of defined cutting edge, as distinct from standard filtration in measurements of surface irregularities. Differences resulting from both formulations are outlined as well as the method of determining the frequency of component separation for surface roughness and waviness.

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Authors and Affiliations

Adam Boryczko
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Abstract

Movement is one of the most spectacular phenomena involving glaciers. Deter- mining glacier surface velocity is now a routine aspect of glaciological studies. These are geodetic methods, especially satellite positioning, that most frequently is applied in such work. Using the Hans Glacier (SW Spitsbergen) as an example, the presented paper is an attempt at defining the time resolution limit of changes in the velocity determined using GPS positioning technology. A test network was established in the area of the examined glacier in order to define the size and variability of the main satellite positioning biases as well as to define their impact on determining position and the calculated velocity. A discussion relating to achieved accuracy (differentiated from measurement precision) for baselines of a length of several kilometres in the high latitudes has also been presented.
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Authors and Affiliations

Marcin Rajner
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Abstract

The paper presents investigation into the single water microjet surface cooling producing evaporating film. Reported tests were conducted under steady state conditions. Experiments were conducted using the nozzle size of 70 and 100 μm respectively. In the course of investigations obtained were experimental relations between heat flux and wall superheating. It was proved that the phenomenon is similar to that of pool boiling but the boiling curves are showing a smaller value of critical heat flux (CHF) that the stagnant pool boiling. Values of CHF are also reduced with decreasing liquid subcooling. Theoretical model of surface cooling by evaporating microjet impingement in the stagnation point was described theoreticaly. Results of experiments were compared with predictions by the model showing a good consistency.
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Authors and Affiliations

Dariusz Mikielewicz
Jarosław Mikielewicz
Tomasz Muszyński
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Abstract

The thermochemical treatment applied to improve the surface properties of AZ91 consisted in heating the material in contact with AlSi10Mg powder at 445 oC for 30 min. During heat treatment process the powder was held under pressure to facilitate the diffusion of the alloying elements to the substrate and, accordingly, the formation of a modified layer. Two pressures, 1 MPa and 5 MPa, were tested. The resultant layers, containing hard Mg2Si and Mg17Al12 phases, were examined using an optical microscope and a scanning electron microscope equipped with an energy-dispersive X-ray spectrometer (EDS). The experimental data show that the layer microstructure was dependent on the pressure applied. A thicker, three-zone layer (about 200 μm) was obtained at 1 MPa. At the top, there were Mg2Si phase particles distributed over the Mg17Al12 intermetallic phase matrix. The next zone was a eutectic (Mg17Al12 and a solid solution of Al in Mg) with Mg2Si phase particles embedded in it. Finally, the area closest to the AZ91 substrate was a eutectic not including the Mg2Si phase particles. By contrast, the layer produced at a pressure of 5 MPa had lower thickness of approx. 150 μm and a two-zone structure. Mg2Si phase particles were present in both zones. In the upper zone, Mg2Si phase particles were regularly distributed over the Mg17Al12 intermetallic phase matrix. The lower zone, adjacent to the AZ91, was characterized by a higher volume fraction of Mg2Si phase particles distributed over the matrix composed mainly of Mg17Al12. The alloyed layers enriched with Al and Si had much higher hardness than the AZ91 substrate.

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Authors and Affiliations

R. Mola
M. Cieślik
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Abstract

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.

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Authors and Affiliations

D. Bańkowski
ORCID: ORCID
S. Spadło
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Abstract

Since fatigue cracks nucleate and initiate generally at the surface of the rotary components such as blades and discs, the surface condition is the most important factor affecting the fatigue life. Surface scratches are suitable sites for stress concentrations and therefore the nucleation stage of fatigue cracks will be shortened. In the present work, the influence of surface roughness on the low cycle fatigue life behavior of nickel-based superalloy Rene®80 at the temperature of 900°C was evaluated. Results of low cycle fatigue tests (LCF) under strain-controlled condition at 900°C for R = εmin/εmax = 0 and strain rate of 2×10 –3 s –1, at a total strain range of 1.2% showed an inverse relationship between fatigue strength and surface roughness of the specimens. In this study, increasing the surface roughness of Rene®80 from 0.2 μm to 5.4 μm led to the decline in the final LCF life from 127 cycles to 53 cycles which indicated a 58.3% reduction in fatigue life at the same condition. Fractography evaluation also exhibited that fatigue cracks initiated from the notch in the rough specimens, whereas in the smooth specimen fatigue cracks nucleated from the internal imperfections and carbides.
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Authors and Affiliations

Mohammad Mehdi Barjesteh
1
ORCID: ORCID

  1. Malek Ashtar University of Technology (MUT), Faculty of Material and Manufacturing Technologies, Tehran 15875-1774, Iran

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