Material Surface Roughness Research Articles

Modeling and analysis for material removal and surface roughness in fluid jet polishing of optical glass

Fluid jet polishing (FJP) is a non-contact polishing technology that can fabricate free-form optical surfaces with sub-micron-level form accuracy and nano-level surface roughness, especially for hard and brittle materials. The surface generation model of FJP can be used to guide the determination and optimization of process parameters and is of great significance for understanding the evolution mechanism of surface microtopography. However, predictive models for the microscopic topography of polished surfaces are still lacking. This study established a macroscopic surface profile model for predicting 3D material removal characteristics and surface texture by combining the 3D computer fluid dynamics (CFD) simulation model and single-particle erosion mechanism. A fractal theory-based erosion model has been built to calculate the material removal caused by the erosion of a single abrasive particle on the rough surface; thus, it predicts the micro-topography and surface roughness of the polished samples. A series of polishing experiments were conducted to analyze the feasibility and accuracy of the model quantitatively and study the influence mechanism of process parameters on the material removal characteristics and surface quality. Results indicated that the models could well predict material removal and surface roughness. The prediction accuracy of the surface roughness Ra and maximum removal depth is better than 91.6% and 90%, respectively. It is also found that the material removal rate of FJP could reach 0.517 mm3/min, and the surface roughness convergence rate could reach 62.9%.

Investigation on Influence of Die Electric Medium in Electrical Discharge Machining of Monel 400 Alloy

Electrical Discharge Machining (EDM) is a non-conventional thermal energy based erosive process, which primarily applied for machining hard materials. Material Removal Rate (MRR) and surface roughness are the response parameters used to characterize the dielectric nature of the machined surface in EDM process. Addition of ingredients in the dielectric fluid improves the properties of fluid for better machining of the samples. The dielectric fluid medium plays a key role in controlling the electrical discharge and heat absorption, thereby removes the debris and cools the work piece during the machining process. In the current study, comprehensive work is done by investigating the effect of different dielectric fluid medium on machining parameters of EDM process with the addition of different powders in the dielectric fluid, which results in high precise and better topography in the machined part surface. Addition of powders such as Titanium (Ti), Silicon (Si), Graphite (Gr), Copper (Cu) and Aluminium Oxide (Al2O3) in dielectric fluid increases the convection property in the work piece tool interaction with increase in the micro-hardness of material. This work analyses the performance study of Electrical Discharge Machining (EDM) of Monel 400 alloys, which can be improved by adding metallic powder into the dielectric medium. Material Removal Rate (MRR) is measured in the samples machined out of EDM process. In addition, Taguchi L27 Orthogonal Array is formulated for conducting machining in a sequential order to understand the implications of machined process parameters on the material removal rate over different dielectric mediums. It is found that the Aluminium oxide, graphite powder mix with EDM oil gives better material removal rate and less machining time. Furthermore, the introduction of Cu powders in the dielectric fluid provides better machinability response parameters. But it is preferable to parts with high slenderness ratio especially holes.

Investigation of the Surface Roughness and Hardness of Different Denture Teeth Materials: An In vitro Study

ABSTRACT Background: Surface roughness and hardness are key factors that influence the clinical performance and durability of denture teeth. Understanding variations in these properties among different denture teeth materials can assist in selecting the most suitable materials for optimal patient outcomes. This study aimed to investigate the surface roughness and hardness of four commonly used denture teeth materials: acrylic resin, composite resin, porcelain, and nanohybrid composite. Materials and Methods: Ten specimens were prepared for each denture teeth material, resulting in a total of 40 specimens. Surface roughness was assessed using a profilometer, and measurements were recorded in micrometers (μm). Hardness was determined using a Vickers hardness tester, and results were expressed as Vickers hardness numbers (VHN). The surface roughness and hardness data were analyzed using appropriate statistical tests (e.g., analysis of variance), with significance set at P < 0.05. Results: The results revealed significant differences in both surface roughness and hardness among the different denture teeth materials (P < 0.05). Acrylic resin exhibited the highest surface roughness (mean ± standard deviation: 3.45 ± 0.78 μm) and the lowest hardness (mean ± standard deviation: 45.6 ± 2.3 VHN). Composite resin demonstrated intermediate values of surface roughness (mean ± standard deviation: 1.87 ± 0.54 μm) and hardness (mean ± standard deviation: 65.2 ± 3.9 VHN). Porcelain demonstrated the smoothest surface (mean ± standard deviation: 0.94 ± 0.28 μm) and the highest hardness (mean ± standard deviation: 78.5 ± 4.1 VHN). Nanohybrid composite displayed surface roughness and hardness values similar to composite resin. Conclusion: This study demonstrated significant variations in surface roughness and hardness among the different denture teeth materials evaluated. Acrylic resin exhibited the roughest surface and lowest hardness, while porcelain demonstrated the smoothest surface and highest hardness. Composite resin and nanohybrid composite exhibited intermediate values. These findings provide valuable insights for prosthodontic practitioners in selecting denture teeth materials based on specific clinical requirements, aiming to achieve optimal aesthetics, reduced plaque accumulation, and improved wear resistance.

Investigation of machining rate and surface roughness in wire EDM of Al6063/WC/ZrO2 composite using response surface methodology

The aim of the current work is to explore the machinability behavior of Al6063/WC/ZrO2 metal matrix composites (MMC) produced through a stir casting process through wire electrical discharge machining (WEDM) process. In order to examine the effects of process parameters such as voltage (V), pulse on time (Ton) and pulse off time (Toff) on material removal rate (MRR) and surface roughness (SR), the experiments were conducted by adapting Response Surface Methodology (RSM) in conjunction with the central composite design (CCD). A second-order regression model has been developed to predict the response parameters and an analysis of variance (ANOVA) was performed to validate the significance of the models. Using the desirability function approach, the parameters were set for the highest MRR and the minimum SR value. The prediction was within a tolerable average error range. A total of 19 sets of tests were developed to obtain six possible solutions. The most suitable solution among these six has been found by a confirmatory experiment. The results indicate that voltage and its interactions have significantly affected both the responses than Ton and Toff. Overall, it can be said that the study of the Al6063/WC/ZrO2 MMCs using WEDM process parameters demonstrated improved casting and machining qualities.

An experimental investigation of F53 super duplex stainless steel using wire cut EDM process

This research focuses on the machinability of F53 super duplex stainless steel using the Wire Electrical Discharge Machining (WEDM) process. F53 Super Duplex Stainless Steel is known for its exceptional corrosion resistance and mechanical properties. It is a popular choice for critical applications in various industries, such as offshore, chemical, and petrochemical. The wire EDM process is chosen for its ability to achieve precise and intricate cuts in hard-to-machine materials like super duplex stainless steel. This study considered important process variables like wire feed rate, servo voltage, pulse-on and pulse-off time, and material removal rate and surface roughness as output responses. Box Behnken method is used to analyse all possible interactions between input and output variables are taken into account, and three different levels of parameter conditions are adopted. It was found that MRR increased by 51.30 % with a gradual increase in pulse on time and applied wire feed and SR decreased by 62.86 % gradually with increasing servo voltage and pulse off time. The optimized values are found to be Ton = 11 µs, WF = 13 m/min, SV = 40 V and Toff = 8 µs. The microhardness study confirms the formation of the melted layer on the machined surface. This research contributes to a deeper understanding of the wire EDM process's applicability to the challenging material properties of F53 super duplex stainless steel, offering insights for the manufacturing and engineering industries aiming to improve the efficiency and precision of machining operations for this advanced material.

Comprehensive review on wire electrical discharge machining: a non-traditional material removal process

A highly advanced thermo-electric machining technique called wire electrical discharge machining (WEDM) can effectively produce parts with varying hardness or complicated designs that have sharp edges and are very difficult to machine using standard machining procedures. This useful technology for the WEDM operation depends on the typical EDM sparking phenomena and makes use of the commonly used non-contact material removal approach. Since its inception, WEDM has developed from a simple approach for creating tools and grown to an outstanding option for creating micro-scale components having the greatest degree of dimensional precision and surface finish characteristics. The WEDM method has endured over time as an efficient and affordable machining alternative that can meet the stringent operating specifications enforced by rapid manufacturing cycles and increasing expense demands. The possibility of wire damage and bent, nevertheless, has severely hindered the process’ maximum potential and decreased the precision as well as effectiveness of the WEDM process. The article examines the wide range of investigations that have been done; from the WEDM through the EDM process’ spin-offs. It describes WEDM investigation that required variables optimization and an assessment of the many influences on machining efficiency and accuracy. Additionally, the research emphasizes adaptive monitoring and control of the process while examining the viability of multiple approaches to control for achieving the ideal machining parameters. Numerous industrial WEDM applications are described with the advancement of hybrid machining techniques. The paper’s conclusion examines these advancements and identifies potential directions for subsequent WEDM research. The investigation on WEDM of metal matrix composites (MMCs) is also reviewed; along with the impacts of various cutting variables like wire feed rate (F), voltage (V), wire tension (WT), and dielectric flow rate on cutting processes outcomes like material removal rate (MRR), kerf width (Kw) and surface roughness (SR). In the present article, future directions for WEDM research were also suggested.

The Effect of some Natural Products as a Denture Cleansers on some Physical Properties of Acrylic Denture Base Material

The study aims to evaluate the effect of some commercially available natural products (soda+ vinegar, soda +thymol , saturated salt solution) in relation to the commercial denture cleansers (Protifex) ,on surface roughness and hardness dimensional accuracy of acrylic denture base materials. one hundred samples were prepared from heat activated acrylic resin denture base material, they are (1cm*1cm*2mm length, width and thickness respectively). After that, half of the samples for each group were immersed for ½ hr per day in the denture cleanser, the other half of the samples immersed for 8 hr per day in the denture cleanser through one month. The denture cleansers used are three solutions prepared freshly everyday for immersion of the samples. The surface roughness of the samples were tested by using Stylus profilometer(Talysurf 10, England), while the hardness of the samples were tested by using Rockwell hardness tester (Wolpert, Germany), the mean is taken for each group and evaluated by using one way analysis of variance test, Dunnet T-test to compare the groups. The results demonstrated that there were no significant differences in the surface roughness and hardness, but with significant difference between treats of length of acrylic resin denture base material and duration of immersion at (P=0.05). All the prepared natural solutions would be accepted in relation to effect on surface roughness , dimensional accuracy, and hardness of acrylic denture base material.

Machining characteristics in ultrasonic vibration-assisted powder-mixed electrical discharge machining of TiN ceramics

This study aims to investigate the application and machining characteristics of brittle conductive ceramics using ultrasonic vibration-assisted powder-mixed electrical discharge machining (UV-PMEDM) technology. Titanium nitride (TiN) ceramics are widely used in aerospace, biomedicine, and electronics due to their excellent properties. However, the conventional mechanical machining methods of these materials result in severe tool wear, high costs, and low efficiency. Although electrical discharge machining (EDM) can overcome some limitations, it typically exhibits a low material removal rate and poor surface quality. This study utilizes the UV-PMEDM technology to process TiN ceramics. Single-factor experiments are conducted to analyze the effects of processing parameters, including ultrasonic amplitude, powder concentration, pulse-on time, and pulse-off time, on the material removal rate, surface roughness, and relative electrode wear rate, which indicate the EDM processing performance. With the assistance of ultrasonic vibration and mixed powders, the material removal rate of TiN ceramics using UV-PMEDM reaches 0.50 mm3/min, while maintaining a relative electrode wear rate below 1 % and surface roughness lower than 4.2 μm. The synergistic combination of ultrasonic vibration and mixed powders significantly enhances the processing efficiency and reduces surface roughness of TiN ceramics. These findings contribute to a better understanding of machining strategies for brittle conductive ceramics.

Effects of post-polymerization conditions on color properties, surface roughness, and flexural strength of 3D-printed permanent resin material after thermal aging.

To evaluate the color, surface properties, and flexural strength of 3D-printed permanent crown resin subjected to different post-polymerization conditions after artificial aging. Ninety (10×2mm) disc-shaped specimens were printed by using permanent crown resin with SLA technology. Specimens were divided into nine different groups, subject to post-polymerization conditions at three different times (15, 20, and 30min) and three different temperatures (40, 60, and 80°C) (n = 10). Color and surface roughness measurements were repeated pre-post thermal aging (5.000 cycles, 5-55°C) and a flexural strength test was carried out. Data were analyzed with Shapiro-Wilk, Kruskal-Wallis, ANOVA, Tukey HSD, and Dunn tests (α<0.05). ΔE00 values showed results below the acceptable color threshold, except for the 30min 40°C group (ΔE00 <1.8). No difference was found between the relative translucency parameter and surface roughness values of the 20min 60°C group recommended by the manufacturer and the other groups. A significant difference was found between the flexural strength values of the groups (p<0.001). The color properties, surface topography, and mechanical properties of the printed permanent crown material were affected by different post-polymerization conditions: polymerized at different times and temperatures. Although the flexural strength and color change values showed promising results, more studies are required to evaluate its suitability for clinical use.

Effect of Different Disinfecting Agents on Surface Roughness and Color Stability of Heat-cure Acrylic Denture Material: An In Vitro Study.

The current study aimed to determine the impact of three different disinfectants on the surface roughness and color stability of heat-cure acrylic denture material. Using a stainless-steel mold, disc-shaped wax patterns with dimensions of 10 mm in diameter and 2 mm thick (in accordance with ADA Specification No. 12) were created and prepared for a total of 75 acrylic samples. Dimensions of all 75 acrylic samples were checked with a digital Vernier caliper. About 25 samples of denture base material were immersed in three different chemical disinfectants: Group I: immersed in chlorhexidine gluconate solution, group II: immersed in sodium hypochlorite solution, and group III: immersed in glutaraldehyde solution. All samples were scrubbed daily for 1 minute with the appropriate disinfectant and submerged for 10 minutes in the same disinfectant. Between disinfection cycles, samples were kept in distilled water at 37°C. Color stability was measured using a reflection spectrophotometer. Surface roughness values were measured by a profilometer at baseline following 15 days and 30 days. After 15 days, the color stability was better in chlorhexidine gluconate solution group (4.88 ± 0.24) than sodium hypochlorite solution (4.74 ± 0.18) and glutaraldehyde solution group (4.46 ± 0.16). The mean surface roughness was less in glutaraldehyde solution group (2.10 ± 0.19), followed by chlorhexidine gluconate solution group (2.48 ± 0.09) and sodium hypochlorite solution group (2.64 ± 0.03). After 30 days, the color stability was significantly better in chlorhexidine gluconate solution group (4.40 ± 0.02), followed by sodium hypochlorite solution (4.06 ± 0.16) and glutaraldehyde solution group (3.87 ± 0.17). The mean surface roughness was significantly lesser in glutaraldehyde solution group (2.41 ± 0.14), followed by chlorhexidine gluconate solution group (2.94 ± 0.08) and sodium hypochlorite solution group (3.02 ± 0.13). In conclusion, the color stability was significantly better in chlorhexidine gluconate solution group than sodium hypochlorite solution and glutaraldehyde solution group. But the surface roughness was significantly lesser in the glutaraldehyde solution group, followed by the chlorhexidine gluconate and sodium hypochlorite solution group. The maintenance of the prosthesis requires the use of a denture disinfectant; therefore, it is crucial to select one that is effective but would not have a negative impact on the denture base resin's inherent characteristics over time. How to cite this article: Kannaiyan K, Rakshit P, Bhat MPS, et al. Effect of Different Disinfecting Agents on Surface Roughness and Color Stability of Heat-cure Acrylic Denture Material: An In Vitro Study. J Contemp Dent Pract 2023;24(11):891-894.

Statistical model of electronic structure in InAs, InP, GaSb, and Si quantum dots with surface roughness

Simulations based on the sp 3 d 5 s * empirical tight-binding method were performed to provide a statistical understanding of the electronic structures and bandgap distributions of III–V (InAs, InP, GaSb) and IV (Si) semiconductor quantum dots (QDs) with surface roughness. The electronic states and wavefunctions of QDs with surface roughness of different sizes, shapes, and materials were computed. The effects of surface roughness on the electronic structures and the bandgap distributions of QDs were investigated. The results show that the bandgaps of QDs of considered materials/sizes/shapes increase on average when introducing surface roughness. It is shown that the simulated bandgap distributions of QDs with surface roughness can be reproduced by a simple model formula, which can be applied to different materials, sizes, and shapes. The model formula was derived by assuming that removing and adding of one atom procedures are independent random processes.

Effect of Beverage Solutions on Surface Roughness of PEEK CAD –CAM, 3D Printing Denture Base and Heat Cure Acrylic Resin Denture Base Materials

The Aim: The aim of this research was to investigate how distilled water, tea, coffee, and cola affected the surface roughness of poly ether ether ketone CAD-CAM, 3D printing, and heat cure acrylic resin denture bases at specific intervals (6 ,12days). Materials and Methods: Disk shape 10 mm (diameter) ×2 m m (thickness), manufactured from materials used which were PEEK, 3D printing and heat cure acrylic resin. Total number of samples are n= (75) samples, control samples not immersed in beverage media n= 15, experimental samples immersed in beverage solutions (distilled water, tea, coffee and cola) n=60 for evaluating the surface roughness at (6, 12 and 24 days) .Then all collecting data were statically analyzed by spss v ersion 25, by means of descriptive statistics, analysis of variance (ANOVA) and duncan multiple range tests at p ≤ 0.05. The Results: The results revealed a significant increase in surface roughness in all beverage solutions at p ≤ 0.0 5. Conclusions: All beverage solutions had a negative effect on surface roughness of all experimental materials, the surface roughness increased. cola had the most aggressive effect followed by coffee then tea and distilled water have the least ef fect.

Experimental investigation of productivity and surface integrity features in trim cut WEDM operation of hybrid metal matrix composite

Present study is focused on optimization of WEDM process parameters for increased productivity and improved surface quality of the machined surface of hybrid composite [Al6061 (90 %), SiC (2.5 %) and TiB2 (7.5 %)] by utilizing the trim cut strategy. Effects of four factors namely, pulse on time (Ton), peak current (Ip), wire offset (WO) and rough-cut history (RCH) have been investigated on response characteristics namely, material removal rate (MRR), surface roughness (SR) and Recast layer (RL) thickness; using Box-Behnken design (BBD) for the experimentation. Three levels of RCH i.e., high, medium and low have been included to investigate the effectiveness of trim cut strategy for dealing with rough-cut surface under varied conditions. The optimized parametric setting has been obtained for multiple responses using desirability function. RCH is found to be most significant factor for MRR, while pulse on time (Ton) is found most significant for SR and RL. WO has been found to play an important role in controlling the thickness of RL. It is observed that after trim cut, surface roughness is improved for experiments conducted under high and medium levels of RCH. However, almost no improvement in SR is obtained for low level of RCH. Trim cut strategy is also found to be effective in reducing the thickness of recast layer, however, it is noticed that the percentage reduction in recast layer thickness for samples machined under high level RCH is greater than that for the other two levels of RCH.

Supercooling degree decrease of barium hydroxide octahydrate employing 3D porous silver foam as supporting material

Inorganic hydrated salts possess high latent heat of phase transition and are promising phase change materials (PCMs). However, the issues of supercooling, low thermal conductivity, susceptibility to leakage, and phase separation significantly impediment the practical applications of inorganic hydrated salts. In this study, it is proposed to decrease the inorganic hydrated salt supercooling degree by increasing the surface roughness of the porous material and to load the nucleating agent silver (Ag) onto polydopamine (PDA) modified melamine foam (MF) by electroless plating to obtain 3D porous Ag foams, which are then utilized as support materials. The results demonstrated that the 3D porous Ag foam compounded with barium hydroxide octahydrate (BHO) can ameliorate the shortcomings of leakage and reduce the supercooling degree in the cooling process. The composite not only exhibits high enthalpy of over 248.5 J/g and high thermal conductivity of 1.82 W·m−1·K−1 but also has a low supercooling degree of 0.21 ℃. Furthermore, the composites exhibited superior shape stability and thermal cycling stability. This study provides an effective method for reducing the supercooling degree of inorganic hydration salts.

Investigating the relationship between surface roughness and reflectance properties of building materials

Materials used in the exterior envelope of buildings and open urban surfaces, in general, strongly affect the urban thermal balance, determining the general magnitude of urban overheating. The surface temperature of reflective materials varies as a function of physical and geometrical properties. Quantifying the influence of surface roughness on reflectance properties has crucial relevance since reflectance can significantly affect the reduction of the absorbed solar radiation and, in turn, the energy demand for cooling. Through an experimental and statistical investigation, this research aims to analytically assess the impact of surface roughness on the reflectance and thermal performances of building materials and, in turn, the role that roughness could play towards urban cooling and mitigation. Results show that the surface’s different roughness affects the sample’s reflectance coefficient, leaving it basically unchanged in the Ultraviolet and Visible ranges but with appreciable differences in the Near-Infrared wavelengths. This outcome confirms the correlation between the surface roughness and the optical and thermal characteristics of the building materials, making evident the importance of the study of superficial topography towards the mitigation of Urban Heat Island phenomena.

Comparative evaluation of probiotic solutions on surface roughness and microhardness of different restorative materials and enamel.

This research study aimed to investigate the impact of probiotic mouthwash and kefir on the surface characteristics, specifically surface roughness and microhardness, of different restorative materials, as well as permanent and deciduous tooth enamels. Thirty disc-shaped specimens were prepared from composite resin (G-ænial Posterior (GP)), polyacid-modified composite resin (compomer) (Dyract-XP (DXP)), and resin-modified glass ionomer cement (Ionoseal (IS)). Additionally, thirty specimens of enamel were obtained from permanent teeth (PT) and thirty from deciduous teeth (DT) by embedding buccal and lingual sections, acquired through vertical sectioning of 15 permanent and 15 deciduous human tooth crowns in the mesiodistal orientation within acrylic resin blocks. The specimens were then categorized into three distinct groups and immersed for 14 days in one of the following solutions: distilled water, kefir or probiotic mouthwash. The mean surface roughness values of all specimens were assessed using an atomic force microscope, while the mean surface microhardness was measured using a Vickers hardness measuring instrument. The results revealed a statistically significant difference in mean surface roughness among the various restorative materials (p < 0.001). Among the restorative materials, the IS material exhibited notably higher mean surface roughness values than other restorative materials and tooth enamel, while no significant differences were observed between the PT and DT groups. Importantly, the main effect of the solutions under investigation was not statistically significant (p = 0.208). No significant difference was found between the surface roughness values of specimens subjected to the different solutions. When evaluating the effects of materials and solutions on microhardness, the main effects of material and solution variables and the influence of material-solution interactions were statistically significant (p < 0.001). Taken together, these results indicate that consistent use of kefir or probiotic mouthwashes may impact the surface properties of various restorative materials and tooth enamel.

Evaluation of Effect of Tooth Brushing on the Surface Roughness of Different Implant Superstructure Materials: An In Vitro Study

Background This in vitro investigation aimed to evaluate and contrast the surface roughness of various implant superstructure materials before and after tooth brushing simulation.Objectives To evaluate the surface roughness of G1- PMMA Polymethyl Methacrylate G2- Polychrome composite and G3- Direct Metal Laser Sintering DMLS glazed Porcelain-Fused-to-Metal PFM restorative materials before and after brushing simulation.Methodology Six cuboid shaped specimens 10times10times2 mm were prepared from prepolymerized CADCAM Computer-aided design and Computer aided manufacturing PMMA CADCAM polychrome composite and conventional DMLS glazed porcelain fused metal N24. The specimens were subjected to 10000 brushing cycles simulating one year of tooth brushing using SD Mechatronik-Brushing Simulator ZM-3.8 and toothbrush amp toothpaste Colgate Palmolive Ltd. The surface roughness Ra was measured before and after brushing using Mitutoyo Surftest SJ-310 surface roughness analyzer.Results No significant change in surface roughness was found on CADCAM Polychrome composite after one year of simulated tooth brushing P gt0.05. However CADCAM PMMA and DMLS PFM demonstrated a significant increase in surface roughness P lt0.05.Conclusion Brushing led to an increase in the surface roughness of CADCAM PMMA and DMLS PFM. All surface roughness values were above the clinically acceptability threshold of 0.2 microm.

Preparation and Performance Testing of Green Non-toxic Polishing Solution for Medical Titanium Alloy

To obtain the lower toxic residue on the medical titanium alloy surface in chemical mechanical polishing process, a new green polishing solution was proposed and evaluated in this study. The humoral fluid was selected as the basic solution in which the silica abrasive particles were used for the grinding particles, and the H2O2 was added as the oxidant. A chemical mechanical polishing test was carried out for its performance investigation with titanium alloy material. Then the surface roughness and material remove ratio of test samples were analyzed and compared with that of existed polishing solution condition. At last, the toxic residue of the titanium alloy samples was obtained by scanning electron microscopy technology. The experimental results indicated that the better material removal rate and surface roughness of medical titanium alloy with humoral polishing solution are obtained comparing with existed polishing solution condition. More importantly, the content of toxic elements on the sample surface was significantly reduced due to the more aluminum and vanadium ions dissolved in polishing solution, which is more beneficial for its application in the medical prosthetics field. This study provides a new reference for the toxic residue reduction on the material surface of medical titanium alloy in chemical mechanical polishing process.

Sustainable electric discharge machining using alumina-mixed deionized water as dielectric: Process modelling by artificial neural networks underpinning net-zero from industry

The requirement for materials possessing both high strength and low density has garnered significant attention from industries and researchers in recent times. Among these materials, aluminum 6061 (Al6061) exhibits the desired properties. However, due to its diverse machining capabilities, powder-mixed electric discharge machining (PMEDM) has emerged as a viable option for cutting such materials. This method has been criticized for its high energy consumption and limited cutting efficiency. Furthermore, conventional dielectric (kerosene) employed in EDM has drastic environmental and operator's health concerns. To address the abovementioned issues, deionized water has been employed in this study which enhances the reusability of resources and minimizes the cost of the dielectric. Herein, to make the process sustainable, and to keep the environment free from hazardous fumes, generated during the machining process, deionized water has been used. In addition to that, to uplift the machining responses, alumina (Al2O3) nano-powder has been engaged. To conduct the study, response surface methodology (RSM) was employed. This investigation aimed to analyze the impact on the material removal rate (MRR), surface roughness (SR), and specific energy consumption (SEC) by using microscopy analysis, scanning electron microscopy (SEM), 3D surfaces profilometry, energy dispersive x-ray (EDX) analysis and after that, the machining responses are modelled using the artificial neural networks (ANN) technique. It was observed that by utilizing non-dominated sorting genetic algorithms (NSGA-II) an improvement of 87.42 % in MRR, 3.4 % better surface finish and 0.7 % better SEC have been obtained. Notably, CO2 emissions were found to be 94.27 % lower by using the deionized water as dielectric compared to those produced by kerosene oil.

Surface Modification of Magnesium Alloy AZ91D Using Nanopowder Mixed Electrical Discharge Machining for Biodegradable Implant.

Powder-mixed electrical discharge machining (PMEDM) enhances the effectiveness of the electric discharge machining process. It has been used on the Mg alloy AZ91D to address biodegradation concerns in implants. By combining nano-conductive powder particles with the dielectric fluid, PMEDM creates a functional surface. Process parameters like pulse on time, pulse off time, peak current, and powder concentration are examined to optimize material removal rate (MRR), surface roughness (SR), and white layer thickness (WLT). The optimization of input parameters was completed using the Taguchi L9 technique and further analyzed using ANOVA technique that illustrates Ton and pulse-off time as more significant process parameters for powder mixed electric discharge machining as compared with electric potential and peak current. The optimal surface roughness value is found to be 2.215 μm at 3A pulse current and 15 μs Toff time which suggest the material to be suitable for implants.