Evaluation Of Surface Quality Research Articles

Application of Surface Quality Evaluation Method Based on Visual Inspection of Secondary Lining Concrete of NATM Tunnel and Approach to Surface Quality Improvement

NATMトンネルの二次覆工コンクリートは，部材が薄く，セントル型枠と地山との閉鎖空間にコンクリートを充填する施工の難しい部位である。その施工の難しさも一因となって，供用されている構造物では様々な変状や不具合が散見されている。そこで，新設の構造物では覆工コンクリートの表層部の品質を目視調査に基づいて合理的に評価する方法を用いてPDCAサイクルを回し，品質向上を図る試みがなされている。本報告では，東北地方で建設されたNATMトンネルの二次覆工コンクリートを対象として，目視調査に基づく表層品質評価の結果に関する分析および品質確保・向上に関する試みについて現場の事例について紹介する。

Vision system with high dynamic range for optical surface defect inspection.

We report a machine vision system with high dynamic range designed for optical surface defect inspection. The system consists of two motorized linear stages and one motorized rotation stage for automatically scanning the surface. As the intensity of long scratches and digs differ a lot under dark-field illumination, gains of red, green, and blue channels are set to be different values to extend the dynamic range of an ordinary colored detector in a single snapshot, which greatly improves the efficiency compared with multiexposure-based approaches. Image stitching is then employed to get a high-resolution image of the entire optical surface for further processing to quantitatively evaluate surface quality based on the standards of MIL-PRF-13830B and ISO 10110-7:2008. The system can be widely applied in the optical industry, as it provides a low-cost solution for optical surface quality checks.

Utilization of cluster analysis in the multi-dimensional evaluation of mould surface quality in product correlation

Quality assessment of mould surfaces, of the products they produce is often done in both scientific and industrial practice separately and without considering the links of the individual descriptive parameters.The present article will describe how to find amplitude, frequency parameters that will be grouped into so-called parametric sets. Each parameter set will be characterised by its values for both the mould and the product it produces.The final step is to apply cluster analysis and to determine the similarity of the individual sets of parameters between the form and its product.Therefore, the presented methodology will provide complex correlation evaluation of products and mould not by individual parameters but within the whole set of parametric sets.

EVALUATION OF BONDING STRENGTH AND SURFACE QUALITY OF WOOD EXPOSED TO ACCELERATED SOAKING

EVALUATION OF BONDING STRENGTH AND SURFACE QUALITY OF WOOD EXPOSED TO ACCELERATED SOAKING

A surface and sub-surface quality evaluation of three cast iron grades after grinding under various cutting conditions

Grinding is one of the most common finishing processes used in the manufacture of metal components that require a combination of both smooth surface finish and tight tolerances. Despite the abundant knowledge concerning this process, specific literature is still scarce regarding the grinding of different cast iron grades. These materials have a wide application in the automotive industry, notably in the manufacture of gears, crankshafts, and valve control shafts. In this sense, this paper presents an experimental study of the peripheral surface grinding of three grades of cast iron grades (gray, nodular, and compacted graphite) with two SiC abrasive grinding wheels. The input variables tested were two values for depth of cut (15 and 30 μm) and two worktable speeds (5 and 10 m/min). The output variables analyzed were surface roughness, microhardness, microstructures, and SEM images of the ground surfaces. The results showed that gray cast iron provided the best performance concerning surface and sub-surface integrity among the three cast iron grades tested, whereas the nodular cast iron exhibited both worst finishing and superficial texture. No microstructural changes were observed in the samples of gray and compacted graphite cast iron grades, irrespective of the cutting conditions investigated, unlike for the nodular cast iron grade in which microstructural change was detected. The ranking order for the grindability of the three cast iron grades in terms of roughness, microhardness and surface texture investigated in this paper is gray cast iron, compacted graphite iron and nodular cast iron.

Influence of End Mill Helix Angle on Surface Quality of Aluminium Thin-Walled Parts

Abstract This paper deals with the influence of the end mill helix angle on the flatness and surface quality of aluminium (EN AW 6082) thin-walled parts. The three teeth solid end mills of 12 mm diameter with same and different helix angle of third tooth were designed. The tests were performed using the HSC 105 linear CNC machine and following cutting parameters: cutting speeds (800, 100 and 1200 m.min−1), feed per tooth (0.12 mm), cutting depth (for roughing 10 mm and for finishing 5 mm). Evaluation of surface quality of the processed thin-walled parts shows that the helix angle of the end mills has a significant influence on the surface quality of the thin-walled parts. The best results were obtained in the case of end mill with different 35° helix angle of third tooth and cutting speed 1000 m.min−1.

Surface Quality Evaluation in Orthogonal Turn-Milling Based on Box-Counting Method for Image Fractal Dimension Estimation

Turn-milling is a relatively new cutting process combining the both advantages of turning and milling, during which the tool and the workpiece rotate simultaneously. Due to the small axial cutting force, turn-milling is especially suitable for the machining of miniature parts. Usually, the surface quality is characterized by roughness, but the size of miniature parts is difficult to meet the requirements of the sampling length, which will have a huge influence on the characterization results. This paper introduces the box-counting method for image fractal dimension estimation to evaluate the surface quality of miniature parts during orthogonal turn-milling. The fractal dimension is an independent parameter for scale, which is not influenced by the sampling length. The effect of cutting parameters on surface quality of miniature parts during turn-milling is also studied.

Dependence of Surface Roughness on Depth of Cut for Aluminum Alloy AlCu4Mg1

Presented article is focused on evaluating surface quality parameters Rz and Ra after turning made by various cutting conditions. Monitored parameters in experimental part were feed rate, cutting speed and depth of cut. Researching optimal cutting conditions, which sets often affect and increase productivity, quality and precision of manufactured products. Aim of the article is to increase quality of current state, what require long time testing and experiences. Article also presents individual comparing of two selected cutting plates in various cutting conditions, when in conclusion are clearly define results of experiment and requirement for practical using in industry.

High-strength and free-cutting silicon brasses designed via the zinc equivalent rule

This study reports on the formation of high-strength and free-cutting silicon brasses designed and adjusted via the zinc equivalent rule by adding Pb replacers (Si and Al elements). Microstructure analysis indicates that phase components of the designed silicon brasses transform from α+β to β and further to β+γ with the increased zinc equivalent induced by increased Si and Al contents, respectively. Meanwhile, many ultrafine intermetallic compound particles are distributed along the grain boundaries of the α and β phases and embedded into the β-phase matrix along with high densities of nanoscale intermetallic compounds distributed in the β-phase matrix close to the grain boundaries. With the increased zinc equivalent, β-phase microhardness and Brinell hardness of the designed silicon brasses increase gradually accompanied by an increase in ultimate tensile strength and a decrease in elongation. Evaluation of chip morphology and machining surface quality imply that α+β brass has good abilities for chip breakage and free-cutting machinability. These results provide significant insight into the microstructural design of high-strength and free-cutting brass alloys.

Evaluation of Surface Quality of Silicone Impression Materials after Disinfection with Ozone Water: An In vitro Study.

Purpose:To compare and evaluate the surface quality of silicone impression materials after ozone water disinfection.Materials and Methods:A total of 60 samples were prepared on a stainless steel die (American Dental Association specification no. 19 and International Standard of Organization - 4823). The samples were divided into four groups; each group contains 15 samples. Group A as control, Group B, C, and D disinfected with 2% glutaraldehyde, 5.25% sodium hypochlorite, and ozone water, respectively. The samples were made according to the manufacturer's instructions, and the samples were allowed to set in a thermostatically controlled water bath at 35°C ± 1°C and retrieved after 10 min. The surface qualities of the samples were measured in stereomicroscope with ×20 magnification.Results:The data obtained were analyzed using Chi-square test, and the “P” value was calculated. The results showed that there were no differences in the surface quality among the Groups A, C, and D for addition silicone putty and light body and medium body impression materials than the Group B.Conclusion:This study concluded that ozone water disinfection showed least changes when compared to 5.25%sodium hypochloride and 2% glutaraldehyde disinfection for addition silicone putty , light body and medium body impression materials.

Investigating the Effect of Approach Angle and Nose Radius on Surface Quality of Inconel 718

This experimental work presents a surface quality evaluation of a Nickel-Cr-Fe based Inconel 718 superalloy, which has many applications in the aero engine and turbine components. However, during machining, the early wear of tool leads to decrease in surface quality. The coating on cutting tool plays a significant role in increasing the wear resistance and life of the tool. In this work, the aim is to study the surface quality of Inconel 718 with TiAlN-coated carbide tools. Influence of various geometrical parameters (tool nose radius, approach angle) and machining variables (cutting velocity, feed rate) on the quality of machined surface (surface roughness) was determined by using central composite design (CCD) matrix. The mathematical model of the same was developed. Analysis of variance was used to find the significance of the parameters. Results showed that the tool nose radius and feed were the main active factors. The present experiment accomplished that TiAlN-coated carbide inserts result in better surface quality as compared with uncoated carbide inserts.

Line-scanning laser scattering system for fast defect inspection of a large aperture surface.

Inspection of defects with micrometer level on large aperture surfaces with hundreds of millimeters is one of the challenges in surface quality evaluation. Various microscopic imaging methods have been applied to inspecting the surface defects, while they are time-consuming for the small field of view and the sub-aperture stitching. To tackle this problem, a high-speed line scanning system based on the dark-field laser scattering method is proposed. The laser beam is scanned by the rotating polygon mirror to a laser line for high throughput and then the telecentric F-theta lens converges each incoming laser beam to a focused spot that creates a high intensity to enhance the signal-to-noise ratio. The scattered light from surface defect is collected by the designed integrating sphere for low background noise and the scattering signal is detected for each focused spot at a proper acquisition rate by a photomultiplier (PMT) detector with extremely short response time. In the meanwhile, the tested surface is moving perpendicular to the laser line to realize high-speed large area inspection. The defect inspection system is confirmed experimentally with laser line length of 60mm, minimum detectable size less than 0.5μm, and figure of merit of 9.6 cm2 s-1 μm-1. The work put forward an effective method for automatic discovery of surface defects such as scratches, digs, and contaminants on large aperture surfaces.

Effect of Honing Parameters on Generated Surface Quality of Cylinder Liner within Automotive Engine Production

One of the key parameter in evaluation of cylindrical surface quality of the engine liners is surface roughness. A large number of process factors affecting a final surface topography, which has direct impact on fuel consumption and CO2 emission. A suitable choice of honing conditions can results not only to better surface quality, but it can contributes to reducing of environmental impacts in automobile transport. Twelve different engine cylinder liners were machined in various combinations of cutting parameters. Experimental testing was realised on real production machine tool, where process factors were cutting speed, machining allowance and stone pressure of honing tool. All factors have 4 levels and parameters of surface roughness CR, CF, CL were selected as a variables and suitable indicators for surface quality assessment. The results show that influence of the tool stone pressure on honed surface is more significant than effect of cutting speed. Effect of machining allowance is negligible as well.

Evaluation of Surface Quality and Signal Characteristics in Milling Process of Al7075-T651

Recently, as the automotive and aerospace industry research has focused one weight lightening, the use of functional aluminum alloys has been increasing. Aluminum alloys are effective materials because of their high specific strength and high stiffness ratio. However, machining deformation and heat deflection can occur depending on the machining type. Owing to these difficult-to-cut characteristics, it is necessary to monitor the machined surface quality of aluminum alloys. In this paper, we study the correlation between surface quality, namely burr formation and surface roughness, related to cutting parameters and signals obtained from multiple sensors. The output signals are measured by an acoustic emission (AE) sensor and an accelerometer and are analyzed in the signal frequency domain. By using the wavelet transform of analyzed signals, we determine the correlation between surface quality and signals. Based on this investigation, a surface quality monitoring system can be suggested.

The prediction of surface roughness of PCBN turning GH4169 based on adaptive genetic algorithm

ABSTRACTSuper alloy is widely used in aerospace, ships, petrochemical, etc. Processed surface quality of super alloy plays a key role in the performances in poor working conditions. Surface roughness is significant in evaluating surface quality, so it is important to establish the prediction model of surface roughness. An adaptive genetic algorithm is proposed for the prediction model of GH4169 surface roughness. According to the theoretical analysis, the prediction model established with adaptive genetic algorithm could effectively predict the surface roughness of turning process of GH4169. Moreover, the prediction model could optimize the turning parameters and to improve the surface quality.

Consistency evaluation of hole series surface quality using vibration signal

The hole series parts is widely used in the aerospace, automotive electronics, instrumentation, and hydraulic components. There are many of holes with the same machining parameter in this kind of parts, the consistency evaluation of these hole surface quality is one of the most important considerations. Based on wavelet packet energy spectrum, higher-order statistics, radar chart, and fuzzy c-means (FCM) algorithm, a method is presented to evaluate hole surface quality quickly and effectively. Vibration signal is used as the main source of information about the drilling process. In this paper, wavelet packet energy spectrum (WPES) and higher-order statistics, which can image the information on both time and frequency domain, are applied as preparatory work for cluster analysis. Then, a ten-dimensional feature vector for cluster analysis is constructed from the value of higher-order statistics and wavelet packet energy ratio of the frequency bands where the energy is abnormal. Finally, cluster analysis based on radar chart and FCM algorithm is conducted on the feature vector for classification. By comparison, it is found that the cluster analysis result is basically consistent with the artificial test result. The proposed method can be further extended to the quality evaluation of other machining processes.

Surface roughness evaluation after machining wear resistant hard coats

The technology HVOF – High Velocity Oxygen Fuel was used to spray the alloy Stellite 6 for the purpose of this research. This method is based on using high velocity spraying flame. The article deals with the evaluation of surface quality after machining of wear resistant hard coats. The goal of the authors was to understand the main factors that influence final surface quality at machining of the coatings from Stellite 6. The findings of experiment have confirmed that there have been obtained very important information about machining of this alloy at the specific type of workpiece. Authors have evaluated the quality of the surface not only by means of Abbott curve, but they have also observed the dependency of arithmetical mean roughness value on both cutting edge radius and feed. The analyses of cutting tips wear at changeable inserts of tools have shown that the typical wear appears in the form of a notch.

Диагностика состояния элементов муфт свободного хода

The article presents the results of theoretical research, which was conducted in the framework of finding solutions task analytical diagnosis of the errors of geometry of the freewheel mechanisms. The solution to this problem enhancing the accuracy and reliability of the assessment of the clutches and provides the increase of reliability of operation and operating mechanisms in General. The authors have developed a new diagnostic method for accurate assessment of the quality of the surface of the rotating cage or hub and rollers. The essence of the method lies in the fact that the assessment of elements of parts of freewheels is made by analyzing the level of noise that is the result of the manifestation of such sources, as defects, are available on the surfaces of these elements. For the detection and classification of defects check emerging bursts recorded at fixed points in time and which can be calculated using the coordinates of location of defects, construction of the hub and the frequency of its rotation. The proposed new technique has been used to assess the condition of parts as one-way mechanisms of metal-cutting machines and roller locks for technological devices. The degree of accuracy produced by the rejection of parts made from 83 % to 89 %. The advantages of the proposed method are the following provisions: 1) the controller is able to determine the total number of defects with a high degree of accuracy; 2) reduced time to assess the wear and deviations of the geometry of the parts of the freewheel mechanisms; 3) accuracy of evaluation of surface quality can be checked by comparison with results of measurements carried out using certified equipment. Present article is one of the first works on vibration diagnostics of the freewheel mecha­nisms. In the article the phenomenological formula for calculating the dimensions of the defects on the parts overrunning roller freewheel mechanisms.

Surface quality evaluation of AISI 4340 steel having varying hardness during machining with TiN-coated CBN inserts

Trends of turning hardened steel are increasing in manufacturing industries because it offers many significant benefits over grinding. One of the main advantages is attaining better surface quality along with high dimensional accuracy. However, during hard turning the friction between tool and workpiece is very high, which results in early tool wear that leads to decrease in surface quality and dimensional accuracy of the finished products. The coating on cutting tool plays a vital role in enhancing wear resistance. Therefore, the aim of this research work is to investigate the surface quality during machining hardened AISI 4340 steel with TiN-coated CBN tools. The process variables selected during experimentation are tool nose radius, workpiece hardness, cutting speed and feed rate. The machining is carried out in dry conditions. The second-order mathematical model of surface roughness has been developed using regression analysis. The significance of the model and influence of the process parameters have been carried out using analysis of variance technique. Results indicate that performance of TiN-coated CBN tools is superior when compared to uncoated CBN tools during machining of hardened AISI 4340 steel.

Influence of Natural Dyes as Dyeing Material on Surface Roughness of Eastern Redcedar

The objective of this study was to evaluate surface quality of Eastern redcedar ( Juniperus virginana L.) samples finished with natural dye produced from the Madder root ( Rubia tinctorium L.] with two kinds of mordants, ferrous sulfate (Fe 2 (SO 4 ) 3 .7H 2 O) with technical grade 96% purity, supplied by Merck and alum KAl 2 (SO 4 ) 3 .18H 2 O (puriss. p.a. Fulka). Surface roughness of the control and finished samples were measured employing a fine stylus type profilometer resulted in two parameters, namely average roughness (Ra) and mean peak-to-valley height (Rz). Finishing materials were applied to the surface of the samples by soaking with and without using ultrasound in a tank. Average value of Ra taken from the surface of unfinished control samples and finished samples were 2.60 μm and 3.25 μm, respectively. It appears that natural dye with alum and ferrous sulfate used as dying materials did not adversely influence overall surface quality of the samples. Based on the initial findings in this work such root dye would have potential as eco-friendly non-toxic colorant to extend the service life of product manufactured from Eastern redcedar.