Investigation on an industrial-feasible approach for measurement and assessment of large-sized micro-structured surfaces based on grayscale matching

Abstract

Multi-scale micro-structured functional surfaces can enhance the interfacial effect on a component by the microtopological structure, likely through realizing or enhancing its lubrication, drag reduction, noise reducing, sealing, and other specific surface functions. However, the realization of these functions requires high-precision machining quality and the occurrence of any defects on the structured surfaces will possibly influence actual performances of the component. The distribution density, morphology, geometry, configuration feature, and position of those microstructures play a decisive role in affecting the functional performance of the component. It imposes a challenge for rapid and accurate measurement of micro-structured surface particularly at a reasonable large size in industrial-scale production. This article presents an innovative industrial-feasible measurement method for micro-structured surfaces using normalized grayscale matching combined with pyramid search strategy, discriminating-step matching strategy, and sensitive area analysis. The method renders the high matching accuracy and rapid processing capability, which also provides the technical solution for industrial-scale micromanufacturing of large-sized micro-structured surfaces. Well-designed experimental trials are carried out to further evaluate and validate the measurement accuracy and efficiency.