3D Surface Roughness Parameters Research Articles

Abrasive Sensitivity of Engineering Polymers and a Bio-Composite under Different Abrasive Conditions.

Two different test systems were designed to evaluate the tribological behavior of five engineering plastics (Polyamide—PA grades and Ultra High Molecular Weight Polyethylene—UHMW-PE) and a fully degradable bio-composite (Polylactic Acid—PLA/hemp fibers) targeted to agricultural machinery abrasive conditions. Pin-on-plate tests were performed with different loads, sliding velocity and abrasive particles. The material response was further investigated in a slurry containing abrasive test system with different sliding velocities and distances, abrasive media compositions and impact angles. The abrasive wear, the change of the 3D surface roughness parameters, the friction force and contact temperature evolution were also analyzed as a function of the materials’ mechanical properties ( and the dimensionless numbers derived from them. Using the IBM SPSS 25 software, multiple linear regression models were used to statistically evaluate the measured data and to examine the sensitivity of the material properties and test system characteristics on the tribological behavior. For both test setups, the system and material characteristics influencing the dependent variables (wear, friction, heat generation) and the dimensionless numbers formed from the material properties were ranked using standardized regression coefficients derived from the regression models. The abrasion sensitivity of the tested materials were evaluated taking into account a wide range of influencing parameters.

Evaluation of Surface Roughness and Defect Formation after The Machining of Sintered Aluminum Alloy AlSi10Mg.

This article presents selected issues related to the workpiece surface quality after machining by the laser sintering of AlSi10MG alloy powder. The surfaces of the workpiece were prepared and machined by longitudinal turning with tools made of sintered carbides. The occurrence of breaches on the machined material surface was found, which negatively influence the values of 3D surface roughness parameters. The occurring phenomena were analyzed and proposals for their explanation were made. Guidelines for the machining of workpieces achieved by the laser sintering of powders were developed. The lowest value of the 3D roughness parameters was obtained for f = 0.06 mm/rev, ap = 0.5–1.0 mm, and for the nose radius of cutting insert rε = 0.8 mm. The results of research on the effect of cutting parameters on the values of parameters describing the surface quality are presented. Topography measurements and 3D surface roughness parameters are presented, as well as the results of a microscopic 3D surface analysis. Taguchi’s method was used in the research methodology.

Image Data-Based Surface Texture Characterization and Prediction Using Machine Learning Approaches for Additive Manufacturing

Abstract The increase in the use of metal additive manufacturing (AM) processes in major industries like aerospace, defense, and electronics indicates the need for maintaining a tight quality control. A quick, low-cost, and reliable online surface texture measurement and verification system are required to improve its industrial adoption. In this paper, a comprehensive investigation of the surface characteristics of Ti-6Al-4V selective laser melted (SLM) parts using image texture parameters is discussed. The image texture parameters extracted from the surface images using first-order and second-order statistical methods, and measured 3D surface roughness parameters are used for characterizing the SLM surfaces. A comparative study of roughness prediction models developed using various machine learning approaches is also presented. Among the models, the Gaussian process regression (GPR) model gives an accurate prediction of roughness values with an R2 value of more than 0.9. The test data results of all models are presented.

Analysis of the Effect of Trochoidal Milling on the Surface Roughness of Aluminium Alloys after Milling

The paper presents the results of the surface morphology of aluminium alloys after milling. The 3D surface roughness parameters Ra, Rz, RSm were examined. Functional relationships between the cutting forces, the torque and the roughness parameters were established. The investigation was carried out with respect to functional characteristics of the surface of aluminium alloys. Two different aluminium alloys: 2024 and 6082, were investigated. Two different milling strategies were employed: milling with a trochoidal tool path and milling with a conventional tool path. Different radial depths of cut were applied in the tests. The percentage of the radial depth of cut was increased every 5 %, from 5 % to 40 %. The results were compared with the conventional machining.

Research of the influence of the 2D and 3D surface roughness parameters of bearing raceways on the vibration level

The level of generated vibrations is one of the most important exploitation parameters of rolling bearings. The vibration analysis allows for the evaluation of the technical condition of new and operating bearing assemblies. There are numerous factors affecting the level of generated vibrations. The condition of topography of active surfaces of rolling bearings is one of them. The state of the surface texture may be described with the use of 2D and 3D roughness parameters. Since there are no unanimous guidelines, the paper’s authors decided to analyse whether, when evaluating topography of the active surface of rolling bearings it is beneficial to measure 3D roughness parameters, or whether the evaluation of 2D roughness parameters fully suffices. Fifth pieces of type 6304 ball bearings were examined. The measurement of selected 2D and 3D roughness parameters of the bearings races was performed using a contact method on a Form Talysurf PGI 1230 device made by Taylor Hobson. The measurement of vibrations generated by the bearings was performed with an Anderometer, a device developed by the employees of the Kielce University of Technology. Statistical analysis based on the correlation calculation was used to evaluate the impact of 2D and 3D roughness parameters of active surfaces of rolling bearings on the level of generated vibrations.

EVALUATION OF SURFACE ROUGHNESS PRODUCED BY NANOCUTTING COPPER STRUCTURE USING A LEAST SQUARE MEAN METHOD

This work performed molecular dynamic simulations to study the 2D profile and 3D surface topography in the nanometric cutting process. The least square mean method was used to model the evaluation criteria for the surface roughness at the nanometric scale. The result showed that the cutting speed was the most important factor influencing the spacing between the peaks, the sharpness of the peaks, and the randomness of the profile. The plastic deformation degree of the machined surface at the nanometric scale was significantly influenced by the cutting speed and depth of cut. The 2D and 3D surface roughness parameters exhibited a similar variation tendency, and the parameters Ra and Rq tended to increase gradually with an increase in the cutting speed and a decrease in the depth of cut. Finally, it is concluded that at the nanometric scale, the 3D surface roughness parameters could more accurately reflect the real surface characteristics than the 2D parameters.

Influence of tool rotation on 3D surface topography at the nanometric scale

ABSTRACTThe influence of the tool rotation on the 3D surface topography produced by the nano-cutting process is investigated using molecular dynamics simulations. The least square mean method is utilized to model the evaluation criteria for the surface roughness parameters. The effects of the tool rotation on the cutting force and the chip formation at the nano-metric scale are also evaluated. It is found that the chip formation produced with tool rotation is dominated by the ploughing and the shearing forces. With increase of the adopted rotation velocity, the cutting force is sharply increased and the smaller elastic recovery of the machined surface is observed. The 3D surface roughness parameters at the nano-metric scale are significantly influenced by the tool rotation velocity and the feed speed, and the surface quality can be improved by decreasing the tool rotation velocity and the feed speed.

Magnetic field assisted finishing process for super-finished Ti alloy implant and its 3D surface characterization

Titanium alloy is used in medical industries due to its biocompatibility. Requirement of implant’s surface roughness and surface topography depends mainly upon its application. In the present study, application of titanium alloy is considered as femoral knee joint implant. The capability of magnetic field assisted finishing (MFAF) process and the polishing tool to provide implant worthy surface is analyzed here. In MFAF process, magnetorheological fluid mixed with abrasive powder in acidic base medium is used as the finishing medium. Characterization of the finished surface is carried out by analyzing 3D surface roughness parameters. The selected 3D surface parameters ( Sa, Spk, Sk and Svk) are considered due to their importance concerning load-bearing articulating surface of knee joint implant. Statistical design of experiment is used for experimental study and subsequently process parameters are optimized. From experimental investigation, the values of Sa, Spk, Sk and Svk are obtained as 11.32 nm, 15.82 nm, 6.51 nm and 41.15 nm, respectively, at optimum process parameter condition. The optimum process parameter values are 901 rpm of the tool, 0.60-mm working gap and 4.30 hrs of finishing time. The obtained values of 3D surface roughness parameters are in the nanometer range and the surface topography will render better wear properties, performance and longer implant life. Further confirmation experiments support the optimized values. The effect of individual process parameter on output responses is also analyzed.

Parametric and nonparametric description of the surface topography in the dry and MQCL cutting conditions

This paper focuses on the parametric and nonparametric description of surface topography after turning in the dry and MQCL conditions. The carried out research involved the longitudinal turning tests of duplex stainless steel, conducted in a range of variable cutting speeds vc and feeds f. Surface topography measurements were conducted with the application of Infinite Focus G4 microscope. In the first stage of research, the parametric analysis of the machined surfaces has been conducted. It included the evaluation of amplitude surface roughness parameters. In the next stage the nonparametric description of machined surfaces was carried out. This analysis has been focused on the presentation of machined surfaces in the form of contour maps and isometric images. The last stage of experiment involved the evaluation of surface isotropy and formulation of material ratio charts. The conducted research shows that the application of MQCL method can lead to the reduction of 3D surface roughness parameters compared to values reached after the dry machining. Moreover, the better distribution of irregularity peaks and pits under the MQCL method, comparing to that obtained after dry cutting implies that surfaces machined with the use of MQCL technique can be characterized by a high wear resistance.

Surface Characterization of Three‐Layer Organic Coating Applied on AISI 4130 Steel

Resin‐bonded molybdenum disulfide (MoS2) is widely applied as a solid lubricant. However, multiple coatings are usually required to meet other requirements in mechanical systems. In this study, a quenched and tempered AISI 4130 steel was used as the substrate, being shot blasted. Furthermore, three layers were successively deposited: a zinc phosphate layer, a phenolic resin (basecoat), and a topcoat based on MoS2. The thicknesses of different layers were obtained by scanning electron microscope and by the ball‐cratering method. 3D surface roughness parameters were determined for each step of manufacturing, following three approaches: average values, isotropy level, and distribution of heights. The ball‐cratering method was successfully applied for determining the thickness of the zinc phosphate but presented a relative deviation for the others layers. The phosphating step was decisive for the final surface topography of resin‐bonded coating in terms of distribution of heights. On the other hand, the isotropy level imposed by the shot blasting of steel was practically unaltered by all manufacturing processes.

Prediction of surface topography in precision hard machining based on modelling of the generation mechanisms resulting from a variable feed rate

The paper presents an original contribution to the prediction of surface topography produced by precision hard turning operations using CBN cutting tools and the variable feed rate of 0.025–0.075 mm/rev. The differences between theoretical and real surface roughness parameters Rz and Sz are quantified in terms of springback effect, additional smoothing of irregularities and side flow effect. The primary experimental study includes measurements of 2D and 3D surface roughness parameters using contact profilometer. Correspondingly, cutting forces were measured using a piezoelectric dynamometer, and based on this data, specific corresponding values of ploughing energy and friction coefficient were determined. It was found that the measured value of maximum height of the surface Sz differs from the theoretical value mainly due to elastic recovery of the machined surface and the smoothing effect at the lower feeds and the elastic recovery and the side flow effect at the higher feeds employed. An empirical model for the prediction of the Sz value in function of the feed rate is derived. The prediction accuracy can be improved by advanced numerical modelling of surface generation mechanisms and associated distortions.

Effects of Technological Parameters on Surface Characteristics in Face Milling

The experimental and theoretic examination of conventional manufacturing procedures continue to be a topic of modern research. It is assisted, to a great extent, by the spread and the possibility of the application of high level software and more accurate measuring equipment. The research results obtained by the use of new equipment can open new ways for further development of conventional manufacturing procedures and their more intensive, more productive application. In this paper, an experimental method is used for examination of the surface features (e.g. flatness, 2D and 3D surface roughness parameters) of face milled aluminium parts. The aim of experiments was to determine the effect of change of the technological parameters (feed rate and cutting speed) on flatness and surface roughness features in of face milling of aluminium parts.

Measuring landscape pattern in three dimensional space

General landscape metrics are mainly conducted in two dimensional space, while the terrain undulation is usually not considered. Terrain fluctuation affects a landscape’s spatial heterogeneity and its spatial-temporal dynamics by diversifying the spatial distribution of soil, vegetation and animals. This article proposed three methods to measure the landscape pattern in three dimensional space, including the 3D derivation of 2D landscape metrics, 3D surface roughness parameters, 3D power spectral analysis and 3D correlation analysis. 3D surface data were designed and validated using the proposed 3D landscape pattern analyzing metrics, and the results indicated that these measurements can effectively evaluate the 3D composition, spatial configuration and texture direction of 3D landscape.

Characteristics of geometric structure of the surface after grinding

This paper presents the technological and functional capabilities of surface textures produced by cutting and grinding operations on hardened steel of about 54 HRC hardness. Special focus was placed on surface textures generated by hard turning and grinding operations which are characterized by the Sz roughness parameter of about 3 - 4 μm and distinctly similar values of the Sa parameter. A set of 3D surface roughness parameters was used to characterize the superficial effects of precision grinding operations and their influence on the parts functionality.

ANALYSIS OF GEOMETRIC FEATURES OF THE 316L STEEL SURFACE AFTER DIFFERENT SURFACE TREATMENT METHODS

The paper presents the selected results of surface quality. The selected 2D and 3D surface roughness parameters are analyzed. An intensive development of various surface topography measuring techniques allows the prediction of the functional attributes of the surface and also evaluation of its quality. The measurement strategy highly influences the results of the evaluation of surface roughness. Finally, some general conclusions are given.

Contact Estimation Using 3D Surface Roughness Parameters

This work is devoted to the elaboration of the new methodology for the wear parts contact estimation using 3D surface roughness parameters defined in the standard ISO 25178-2:2012 for friction and wear rate determination. In our research the random surface model was used, where the height of surface asperities h (x,y) has a normal probability distribution. As a result of research the equations for estimation of the elastic contact area and friction coefficient were derived. The existence of the correlation between friction coefficient and 3D surface roughness parameters was proven as well. The results of this work could have wide practical application, for example in design, for the texture specification on drawings, calculation of load, etc.

Prediction of the Functional Performance of Machined Components Based on Surface Topography: State of the Art

This survey overviews the functional performance of manufactured components produced by typical finishing machining operations in terms of their topographical characteristics. Surface topographies were characterized using both profile (2D) and 3D (areal) surface roughness parameters. The prediction of typical functional properties such as fatigue, friction, wear, bonding and corrosion is discussed based on appropriate surface roughness parameters. Some examples of real 3D surface topographies produced with desired functional characteristics are provided. This survey highlights technological possibilities of producing surfaces with enhanced functional properties by machining processes.

Study on Fabric Surface Roughness and its Influence on Worsted Fabric Abrasion Resistance

Surface roughness is of paramount importance in predicting tactile properties of fabrics. This study aimed at investigating surface roughness and the effect of this property on the abrasion resistance of worsted fabrics. Nine different groups of worsted fabrics were produced. The fabrics had three weave types and three areal densities. A non-contact laser based system was developed to scan the surface of the fabrics. In order to extract the surface roughness profile, a new method of data analysis was presented. Several two dimensional (2D) and three dimensional (3D) roughness parameters were introduced and calculated. Statistical analysis proved that the effect of weave type and weft density was significant on all of the 2D and 3D surface roughness parameters at a confidence range of 95%. However, the 3D parameters provided the surface roughness with just one number in comparison with the 2D ones (warp and weft directions). Therefore, the 3D parameters provided a better indication for the surface roughness which had the effect of both warp and weft directions. Results showed that there was a strong linear correlation between the abrasion resistance and the 3D roughness parameters.

3D Surface Roughness Parameters of Nanostructured Coatings with Application in the Aerospace Industry

This paper presents a study of 3D surface texture measurements and analysis of several surface texture parameters. A stylus measuring instrument was used to measure 3D surface topographies. In experimental part of this study, two coated gas turbine blades used in aerospace industry were chosen to examine surface of the coatings in nano-scale. Surface texture parameters of Ti-Al coating and Ti-Al-N coating were measured and compared to each other. The aim of the research is to analyze the surface of these coatings in an areal (3D) manner. The results indicate slight differences between these two surface textures despite the fact that both are Titanium-based coatings, and the surface of base material for both samples was prepared in the same way before deposition. Further study with repeated measurements of surface texture for deposed coatings has to be made after erosion tests.

The Metrology of Ground Concrete Surfaces Morphology With 3D Laser Scanner

Abstract This paper is devoted to machining of concrete by grinding and the metrology of its surface morphologies. The surface morphology is still open problem from metrological as well as mathematical morphology points of views. In order to understand better abrasive process the raw morphologic state is compared with the ground concrete surfaces. The most significant results are presented in the form of profiles, 3D isometric views and isotropy analysis. Several 3D surface roughness parameters were calculated.