Surface Roughness Research Articles

Scaling Heat Transfer and Pressure Losses of Novel Additively Manufactured Rib Designs

Abstract Rib turbulators are a key cooling feature that enable increased heat transfer on the interior of gas turbine components. As metal additive manufacturing becomes available for developing turbine parts, it is becoming increasingly important to understand how the surface roughness intrinsic to this manufacturing method impacts the performance of rib turbulators. To explore what impact roughness has on rib turbulator performance, several relevant scale test coupons were manufactured on two different additive machines out of IN718. Additionally, several coupons were built at large scales to effectively reduce the relative roughness size impacts and determine scale effects. A range of different wavy broken rib designs, varying both rib wavelength and orientation within a channel were evaluated. Variations between the print methods were found to have limited impact on the surface roughness, but significant impact on the accuracy to meet the design intent with rib heights varying by 30%. Following geometric characterization, coupons were flow tested and it was found that the ribs that more regularly disturbed the flow as a function of their geometry most significantly enhanced heat transfer and pressure drop. The performance index of the broken wavy ribs was similar to other advanced rib designs, such as broken or V shaped ribs, but augmentations to heat transfer and pressure drop were generally lower. The rib performance was compared as a function of relative roughness, and it was found that increases in relative roughness resulted in increased friction factor and heat transfer, especially at higher Reynolds numbers.

Methods for the Viscous Loss Calculation and Thermal Analysis of Oil-Filled Motors: A Review

Oil-filled motors (OFMs) are widely used in deep-sea exploration and oil well extraction. During motor operation, the rotor stirs the oil in the air gap, causing viscous loss. Viscous loss affects the temperature distribution inside the motor. Accurately calculating the viscous loss and temperature rise in OFMs can provide a basis for optimizing the motor’s structural design. Motor structural parameters, including the rotor’s outer diameter, air gap, and slot opening, have a significant impact on viscous loss. The working conditions of OFMs, such as rotor speed and environmental temperature, also affect viscous loss. The viscosity of hydraulic oil is highly influenced by temperature, and changes in viscosity can lead to changes in viscous loss. These changes in viscous loss, in turn, alter the temperature distribution. Therefore, the coupling relationship between viscous loss and temperature must be considered. Additionally, when Taylor vortices occur in the fluid, the surface roughness of the rotor also has a significant influence on viscous loss. Currently, both domestic and international research on viscous loss and thermal analysis struggle to simultaneously consider the coupling of viscous loss and the temperature field, rotor surface roughness, and the effect of motor structure. This paper summarizes the methods used in recent years for studying viscous loss and thermal analysis, and puts forward some suggestions for future research on the coupling of the OFM temperature field and viscous loss.

As-deposited and dewetted Cu layers on plasma treated glass: Adhesion study and its effect on biological response

Improving the adhesion of nanosized copper films to a glass substrate is vital for their application in electronics and medicine, as it enhances their overall reliability. For this purpose, we employed Ar plasma etching (240 s) and magnetron sputtering to create copper layers on a glass substrate. Furthermore, we investigated the effect of subsequent solid state dewetting (at 300 °C) of Cu nanolayers on the interface stability. Increasing the sputtering time resulted in elevated copper concentration, UV-Vis absorption, conductivity, and surface roughness. The as-deposited and dewetted samples exhibited very good wettability with water contact angles below 60°. Importantly, plasma treatment improved the adhesion of the Cu layers to the glass. Subsequent dewetting accelerated surface diffusion and the oxidation of Cu atoms, causing structural and morphological changes. The presence of CuO after dewetting caused loss of the surface plasmon resonance (SPR) band in the UV-Vis spectrum and a decrease in sample conductivity due to the transformation of the copper layer from a metal to an oxide. Biological testing revealed a more pronounced bactericidal effect for the as-deposited Cu layer against E. coli and S. epidermidis on contrary to dewetted samples. The similar cytotoxic trend was observed for human dermal fibroblasts and hepatocytes. Nonetheless, biological testing confirmed better cell adhesion on dewetted Cu layers compared to the as-deposited ones. Therefore, our copper nanostructured samples could find application as antibacterial coatings of biomedical devices.

Advanced pyro-/piezoelectric catalytic disinfection of water via porous spontaneously polarized ceramic with strong local electric field induced by micro-nano bubbles

In-situ electroporation disinfection technology inactivates microorganisms by local electric field penetrating antioxidant membranes without producing by-products, which reduces the consumption of oxidants. However, this individual technology exhibits weak disinfection performance for high water fluxes. Herein, a disinfection system based on the synergy of porous spontaneously polarized ceramic (PSPC) and micro-nano bubbles (MNB) (PSPC/MNB disinfection system, PMDS) was constructed for efficient disinfection of drinking water. Pyro-/piezoelectric effects of PSPC induced by MNB collapse constructed a 1.92 × 108 V/m of local electric field (simulated by COMSOL Multiphysics) and generated reactive oxygen species (ROS; •OH, 1O2, •O2−, and H2O2), resulting in electroporation damage on microorganisms and subsequent fatal oxidation of the intracellular contents by ROS. PMDS completely inactivated 107 CFU/mL of E. coli within 45 min, about 10 times faster than the MNB process, which is attributed to that the abundant porous and rough surface in PSPC increased the specific surface area and dipoles for pyro-/piezoelectric catalysis. Moreover, MNB collapse enriched •OH and induced pyro-/piezoelectric effects of PSPC through local temperature and pressure gradients. Synergistic interaction of PSPC/MNB collected additional thermal and mechanical energies besides the collapse of MNB, and the pyro-/piezoelectricity-induced in-situ electroporation–ROS deep oxidation avoided oxidant consumption and hazardous by-products. PMDS presented favorable disinfection efficiency in actual drinking water source, expected to be a practical system for eliminating microbial hazards in drinking water.

Thermal activation of basic oxygen furnace slag as a heterogeneous catalyst in transesterification: Characterization and catalytic activity studies

The valorization of industrial by-products has garnered significant attention in recent years due to its potential to enhance sustainability and economic efficiency within various sectors. Basic Oxygen Furnace slag (BOF-S), a by-product generated in the steelmaking process characterized by its complex composition, presents an opportunity for waste management and resource recovery. This study investigates the potential of BOF-S as a catalyst in converting waste cooking oil to biodiesel via the transesterification reaction. To improve its efficiency, BOF-S was calcined at 850 °C (BOF-S 850), and 1000 °C (BOF-S 1000), for 5 h. The BOF-S was characterized using XRF, N2 sorption, XRD, TGA-DSC, SEM-EDS and FTIR. The characterization techniques showed that the BOF-S 850 had superior characteristics as a catalyst: rough surface, increased pore size and more active basic sites compared to the BOF-S and the BOF-S 1000 slag samples. The transesterification reaction was conducted at a methanol: oil ratio of 20:1, a catalyst loading of 20 wt %, a reaction time of 12 h, a reaction temperature of 60 °C, and a stirring speed of 750 rpm. The findings established that the BOF-S 850 was the best catalyst, with a 90.77 % biodiesel yield and was able to sustain a maximum of two transesterification cycle runs.

A Novel Size-Based Centrifugal Microfluidic Design to Enrich and Magnetically Isolate Circulating Tumor Cells from Blood Cells through Biocompatible Magnetite–Arginine Nanoparticles

This paper presents a novel centrifugal microfluidic approach (so-called lab-on-a-CD) for magnetic circulating tumor cell (CTC) separation from the other healthy cells according to their physical and acquired chemical properties. This study enhances the efficiency of CTC isolation, crucial for cancer diagnosis, prognosis, and therapy. CTCs are cells that break away from primary tumors and travel through the bloodstream; however, isolating CTCs from blood cells is difficult due to their low numbers and diverse characteristics. The proposed microfluidic device consists of two sections: a passive section that uses inertial force and bifurcation law to sort CTCs into different streamlines based on size and shape and an active section that uses magnetic forces along with Dean drag, inertial, and centrifugal forces to capture magnetized CTCs at the downstream of the microchannel. The authors designed, simulated, fabricated, and tested the device with cultured cancer cells and human cells. We also proposed a cost-effective method to mitigate the surface roughness and smooth surfaces created by micromachines and a unique pulsatile technique for flow control to improve separation efficiency. The possibility of a device with fewer layers to improve the leaks and alignment concerns was also demonstrated. The fabricated device could quickly handle a large volume of samples and achieve a high separation efficiency (93%) of CTCs at an optimal angular velocity. The paper shows the feasibility and potential of the proposed centrifugal microfluidic approach to satisfy the pumping, cell sorting, and separating functions for CTC separation.

Versatile performance of hydrophilic PVDF/CuO nanocomposite membranes for TDS removal in RO reject

ABSTRACT In the current study, by using the phase inversion process, PVDF/CuO nanocompositmembranes with diversified concentrations of copper oxide (CuO) nanoparticles were fabricated to reduce the TDS in RO reject. Consequently, compared to pure PVDF membrane, the hydrophilicity of PVDF membrane bearing 2 wt% of chemically synthesized CuO nanoparticles is higher. This was justified through the contact angle which diminished from 110.9° to 58.2°. The improved hydrophilicity, porosity, and pore size are the vital drivers for the fabricated nanocomposite membranes to exhibit an 81% surge in pure water flux and a 75% rise in permeate flux. Fouling of PVDF/CuO nanocomposite membranes was mitigated by incorporating CuO nanoparticles, decreasing the surface roughness. The antifouling capabilities of the fabricated nanocomposite membranes are enhanced by a higher flux recovery ratio of 97.28. Additionally, the outcomes demonstrated that the nanocomposite membrane performs better in TDS removal, with 89% efficiency in RO reject. Thus, the PVDF/CuO nanocomposite membrane has great prospects in applications necessitating the filtration process.

The effectiveness of chalk as a friction modifier for finger pad contact with rocks of varying roughness

The application of chalk (magnesium carbonate) in rock climbing is common practice as climbers attempt to improve their grip by removing moisture from their hands with the aim of increasing friction at the finger pad-rock interface. This novel work investigated the effectiveness of chalk as a friction modifier on four different rocks (sandstone, granite, dark limestone and light limestone) typically found in areas of the UK where the sport of climbing is undertaken, with varying surface roughness. The static coefficient of friction was measured for dry and wet fingertip conditions with and without chalk, under normal (‘grip’) forces of 5, 10 and 15 N. Results showed that the effectiveness of chalk as a friction modifier is dependent on a number of factors such as moisture level and the gradient of the asperity at the rock surface, however, in general chalk applied to dry fingertips had a more positive effect on the static coefficient of friction than in simulated sweaty conditions. During lab tests, chalk was also seen to be beneficial by making the static coefficient of friction more consistent across most test conditions. The results of this study, and the explanation of friction mechanisms involved, provides guidance for the use of chalk with consideration of the type of rock which is being climbed.

Temperature-irrelevant superhydrophobic polyimide–SiO2 aerogels with a confined shrinkage strategy for high-temperature thermal protection (>400 °C)

Polyimide (PI) aerogels often experience substantial volume shrinkage when exposed to temperatures above 200 °C. Furthermore, research regarding the hydrophobic characteristics of PI aerogels under high-temperature conditions is limited. Herein, a confined shrinkage strategy was proposed, and the PI–SiO2 aerogels were prepared with ultralow thermal shrinkage and high-temperature superhydrophobic properties. Micrometer-sized silica aerogel powders were used in this strategy as shrinkage inhibitors during the production of PI aerogels. The silica aerogel powders were then pulled together using the PI chain and braced to each other, limiting the shrinkage of the PI aerogel matrix attached to the powders. Results indicated that the prepared aerogel experienced a shrinkage of only 6.2 % after heat treatment at 400 °C for 1 h in a muffle furnace. The surface area of the sample decreased from 669 m2/g to 649 m2/g after heat treatment, revealing a reduction of only 2.7 %. Previous studies have never reported this remarkable thermal stability. Furthermore, the aerogel exhibited superhydrophobic properties with a water contact angle of 157.4° and a water rolling angle of approximately 0° at 300 °C due to its high surface roughness.

Optimizing biomimetic hydroxyapatite coating on Ti-6Al-6Mo alloy: Influence of immersion time

Abstract This study investigates the formation and characteristics of hydroxyapatite (HAp) coating on Ti-6Al-6Mo alloy through immersion in a supersaturated calcification solution (SCS) for 3, 7, and 14 days. X-ray diffraction (XRD) and secondary electron microscopy (SEM) with electron dispersive spectroscopy (EDS) were used to identify the phases and characterize the morphology and composition of the HAp layer. Atomic force microscopy (AFM) and contact angle tests were used to evaluate the surface properties, while potentiodynamic corrosion testing in Hanks’ solution was used to assess corrosion behavior. It is confirmed that the sample immersed for 14 days formed an HAp layer on the Ti-6Al-6Mo substrate with a Ca/P ratio of 2.5, approaching the ideal value of 1.67. This HAp film exhibits a smooth and homogeneous crystal structure, with a surface roughness of 31.47 nm and an appreciable corrosion rate of 0.0005 mm/y. This study signifies the impact of immersion time on the microstructural properties and biocompatibility of biomimetic HAp coatings applied to Ti-6Al-6Mo alloy, contributing to the progress of HAp coatings in biomedical engineering.

Biochar-Bio-Cu composite superhydrophobic membrane for efficient oil-water separation

This manuscript presents the development of a superhydrophobic textile fabric (SF) for effective oil–water (O/W) separation. A biochar was synthesized by pyrolysis of banana leaves. The bio-Cu nanoparticles (bio-Cu NPs) were synthesized from grape seed extract. The biochar and bio-Cu NPs were used to enhance the surface roughness of the textile fabric. The low-cost, eco-friendly stearic acid was used as a low surface energy material. The SF achieves a water sliding angle of 1 degree and apparent contact angle of 159 degrees, indicating its superhydrophobic nature. The absorption capacity toward silicone oil (SO), toluene, and crude oil (CO) is measured at 102.2 g/g, 98.5 g/g, and 91.0 g/g, respectively, with minimal decrease after ten usage cycles. The SF exhibits outstanding O/W separation efficiencies for CO (99.6%), toluene (98.9%), and SO (97.5%) over ten cycles. Mechanical stability assessments reveal superhydrophobicity retention till a length of abrasion equal to 650 mm. Chemical stability investigations demonstrate SF’s resilience across a pH range of 1–13 over 2 h of immersion. Furthermore, the SF shows a good flux rate toward the oils used. These findings establish a promising advancement in environmental remediation and O/W separation.

Microstructural evolution and formation of defect complexes in diamond films by nitrogen-containing plasma

Abstract The morphology and crystalline quality of polycrystalline diamond samples were studied by systematically varying the flowrate of nitrogen gas in the microwave plasma. A slight improvement in both crystallite size and crystalline quality is observed for a low concentration of 0.5 sccm nitrogen. With a further increase in nitrogen concentration, diamond switches from micro-crystalline (MCD) to nanocrystalline (NCD) with a nitrogen flow of 2.5 sccm (10% of methane concentration). The surface roughness of the sample is found to depend strongly on the crystallite size of the sample. Extensive spectroscopic studies have been done to understand the presence and formation of different defect complexes in diamond. The presence of nitrogen-containing defect complexes has been studied thoroughly and their concentration has been found to be limited by the solubility limit rather than the availability of reactants in the gas environment. In contrast, the effect these complexes have on the strain of the diamond film is found to be negligible. Optical emission spectroscopy (OES) of the plasma reveals the presence of C2 dimers as well as C-N radicals. However, they have little role in modifying diamond grain morphology or crystalline quality.

IMPACT OF THE WALL-PARALLEL LENGTH SCALE OF ROUGHNESS ON THE DEVELOPMENT OF TURBULENT BOUNDARY LAYERS IN TURBINES

Abstract The detrimental effects of surface roughness on turbulent boundary layers in turbines, and compressors, are well known. Prediction can be problematic, especially for surfaces which are not similar to sand grains. Several publications have proposed additional parameters, slope, skew, etc. to augment a wallnormal measure. Here, we introduce a new roughness parameter, the mean separation, which explicitly measures the average separation between each local minima and its closest local maxima. Scans of turbine blade surfaces have mean separations which are up to six times that of the sand grain surface with the same wallnormal measure. High resolution, < 0.1 μm, area scanning tools and 3-D printing techniques have enabled the development of a “Scan-Scale-Print-Measure” methodology. A surface scan is scaled-up, 3-D printed, applied to a flat-plate and then the turbulent boundary layer is measured. The methodology has enabled parametric studies where the mean separation was increased whilst keeping either the wallnormal or the feature size constant. Both studies demonstrated a surface roughness-loss that was strongly dependent on the mean separation and different to a sand grain correlation. It also showed that for large mean separations the roughness-loss decreased to zero. A study into pits-and-peaks showed that, at the same wallnormal, peaks generated a roughness-loss twice that of pits. An engine representative surface produced only half the roughness-loss that would be attributed to a sand grain surface. The roughness loss was estimated within 5% using the parametric studies.

3D-printed porous titanium rods equipped with vancomycin-loaded hydrogels and polycaprolactone membranes for intelligent antibacterial drug release

Implant-related infections pose significant challenges to orthopedic surgeries due to the high risk of severe complications. The widespread use of bioactive prostheses in joint replacements, featuring roughened surfaces and tight integration with the bone marrow cavity, has facilitated bacterial proliferation and complicated treatment. Developing antibacterial coatings for orthopedic implants has been a key research focus in recent years to address this critical issue. Researchers have designed coatings using various materials and antibacterial strategies. In this study, we fabricated 3D-printed porous titanium rods, incorporated vancomycin-loaded mPEG750-b-PCL2500 gel, and coated them with a PCL layer. We then evaluated the antibacterial efficacy through both in vitro and in vivo experiments. Our coating passively inhibits bacterial biofilm formation and actively controls antibiotic release in response to bacterial growth, providing a practical solution for proactive and sustained infection control. This study utilized 3D printing technology to produce porous titanium rod implants simulating bioactive joint prostheses. The porous structure of the titanium rods was used to load a thermoresponsive gel, mPEG750-b-PCL2500 (PEG: polyethylene glycol; PCL: polycaprolactone), serving as a novel drug delivery system carrying vancomycin for controlled antibiotic release. The assembly was then covered with a PCL membrane that inhibits bacterial biofilm formation early in infection and degrades when exposed to lipase solutions, mimicking enzymatic activity during bacterial infections. This setup provides infection-responsive protection and promotes drug release. We investigated the coating’s controlled release, antibacterial capability, and biocompatibility through in vitro experiments. We established a Staphylococcus aureus infection model in rabbits, implanting titanium rods in the femoral medullary cavity. We evaluated the efficacy and safety of the composite coating in preventing implant-related infections using imaging, hematology, and pathology. In vitro experiments demonstrated that the PCL membrane stably protects encapsulated vancomycin during PBS immersion. The PCL membrane rapidly degraded at a lipase concentration of 0.2 mg/mL. The mPEG750-b-PCL2500 gel ensured stable and sustained vancomycin release, inhibiting bacterial growth. We investigated the antibacterial effect of the 3D-printed titanium material, coated with PCL and loaded with mPEG750-b-PCL2500 hydrogel, using a rabbit Staphylococcus aureus infection model. Imaging, hematology, and histopathology confirmed that our composite antibacterial coating exhibited excellent antibacterial effects and infection prevention, with good safety in trials. Our results indicate that the composite antibacterial coating effectively protects vancomycin in the hydrogel from premature release in the absence of bacterial infection. The outer PCL membrane inhibits bacterial growth and prevents biofilm formation. Upon contact with bacterial lipase, the PCL membrane rapidly degrades, releasing vancomycin for antibacterial action. The mPEG750-b-PCL2500 gel provides stable and sustained vancomycin release, prolonging its antibacterial effects. Our composite antibacterial coating demonstrates promising potential for clinical application.

Behavior of a phase field model for wetting on structured surfaces

AbstractTechnical surfaces are generally not perfectly smooth, but usually exhibit roughness. Additionally, as micro production techniques continue to evolve, geometrical surface structures at the micro scale can be manufactured, which presents a challenge for wetting models that are commonly formulated for smooth surfaces. A phase field model for surface wetting, proposed by Diewald et al., serves as a basis for this investigation. On smooth surfaces, the width of the gas‐liquid interface can be widened for scale bridging purposes, as this allows for accurate computations on coarse grids. However, it was observed that this interface scaling impacts the results when the model is applied to rough surfaces, and therefore a free choice of the interface width is not always sensible. In this work, the ability of the model to deal with sinusoidally shaped surfaces is investigated. An Allen–Cahn evolution equation is used to determine static equilibrium configurations for droplets on such surfaces.

Cyclic Atomic Layer Etching of PdSe2

AbstractThe unique characteristic of 2D transition‐metal dichalcogenide (TMD) semiconductor materials such as PdSe2 is the ability of the bandgap to vary on the basis of the number of layers present. This variation results in a broad bandgap range spanning from semi‐metallic to semiconducting materials, underscoring the significance of precisely controlling the material thickness. In this study, the thicknesses of chemical vapor deposited PdSe2 films are precisely controlled layer‐by‐layer via cyclic atomic layer etching (ALE), which comprised a radical adsorption step generated by oxygen and chlorine plasmas, followed by a desorption step with an organic solvent vapor such as formic acid. Cyclic etching with one monolayer of PdSe2/cycle is achieved using both types of adsorption gases while maintaining the ratio of Se/Pd underlying PdSe2 at ≈2. This cyclic ALE method is also applicable for smoothing TMD material surfaces by isotropically removing individual rough surface layers. Because this etching method only utilizes chemical reactions with radicals generated by plasmas and organic vapors, it is not only unaffected by the physical damage caused by the irradiation of energetic particles such as ions in plasmas, but also is applicable to 3D structure processing.

Synthesis and Characterization of Fe3O4@SiO2 Core-shell Nanoparticles for Mirror and Efficient Magnetic Compound Fluid Polishing of TC4 Titanium alloy

Abstract To fully investigate the polishing performance of the Fe3O4@SiO2 core-shell abrasive for TC4 titanium alloy plate and solve the problem of uneven distribution of abrasive particles in magnetic compound fluid polishing (MCFP) and obtain ultra-smooth titanium alloy surface. In this paper, the functional Fe3O4@SiO2 core-shell abrasives were prepared and characterized by XRD, FTIR, VSM and TEM to demonstrate the successful encapsulation of SiO2 in Fe3O4 first. Second, a new polishing device was built to perform polishing experiments. Four different fractions of Magnetic compound fluid (MCF) were configured and utilized in polishing experiments for MCFP of TC4 titanium alloy to verify the polishing properties. Finally, the contact model between abrasive particles and workpiece is established and the material removal mechanism is discussed. The results show that SiO2 was successfully coated on Fe3O4. The polishing results show that the MCF containing the core-shell structure had the best polishing effect. The surface roughness Ra decreased from 0.201μm to 0.025μm after 20 min of polishing. The surface roughness of TC4 titanium alloy with an initial roughness Sa of 0.248μm is reduced to 0.023μm after polishing by Fe3O4@SiO2 core-shell abrasive. It is shown that the application of core-shell abrasive to process titanium alloys can obtain smooth and defect-free surfaces with good polishing performance. The surface quality of titanium alloy can be improved effectively by using core-shell abrasive, and a new idea for polishing titanium alloy is proposed. This study plays an important role in solving the problem of uneven particle distribution in MCFP. These results pave the way for further research into the application of core-shell abrasives in precision machining and expand the application scope of particles with core-shell structure.

Innovative Application of Salophen Derivatives in Organic Electronics as a Composite Film with a Poly(3,4-Ethylenedioxythiophene)-poly(styrenesulfonate) Matrix

In this work, we present the innovative synthesis of salophen (acetaminosalol) derivatives in a solvent-free environment by high-speed ball milling, using a non-conventional activation method, which allowed obtaining compounds in a shorter time and with a better yield. Furthermore, for the first time, the salophen derivatives were deposited as composite films, using a matrix of poly 3,4-ethylene dioxythiophene:polystyrene sulfonate (PEDOT:PSS) polymer. Significant findings include the transformation from the benzoid to the quinoid form of PEDOT post-IPA treatment, as evidenced by Raman spectroscopy. SEM analysis revealed the formation of homogeneous films, and AFM provided insights into the changes in surface roughness and morphology post-IPA treatment, which may be crucial for understanding potential applications in electronics. The optical bandgap ranges between 2.86 and 3.2 eV for PEDOT:PSS-salophen films, placing them as organic semiconductors. The electrical behavior of the PEDOT:PSS-salophen films undergoes a transformation with the increase in voltage, from ohmic to space charge-limited conduction, and subsequently to constant current, with a maximum of 20 mA. These results suggest the possible use of composite films in organic electronics.

Design and Technological Aspects of Integrating Multi-Blade Machining and Surface Hardening on a Single Machine Base

Modern mechanical engineering faces high competition in global markets, which requires manufacturers of process equipment to significantly reduce production costs while ensuring high product quality and maximum productivity. Metalworking occupies a significant part of industrial production and consumes a significant share of the world’s energy and natural resources. Improving the technology of manufacturing parts with an emphasis on more efficient use of metalworking machines is necessary to maintain the competitiveness of the domestic machine tool industry. Hybrid metalworking systems based on the principles of multi-purpose integration eliminate the disadvantages of monotechnologies and increase efficiency by reducing time losses and intermediate operations. The purpose of this work is to develop and implement a hybrid machine tool system and an appropriate combined technology for manufacturing machine parts. Theory and methods. Studies of the possible structural composition and layout of hybrid equipment at integration of mechanical and surface-thermal processes were carried out, taking into account the basic provisions of structural synthesis and componentization of metalworking systems. Theoretical studies were carried out using the basic provisions of system analysis, geometric theory of surface formation, design of metalworking machines, methods of finite elements, and mathematical and computer modeling. The mathematical modeling of thermal fields and structural-phase transformations during HEH HFC was carried out in ANSYS (version 19.1) and SYSWELD (version 2010) software packages using numerical methods of solving differential equations of unsteady heat conduction (Fourier equation), carbon diffusion (2nd Fick’s law) and elastic–plastic behavior of the material. The verification of the modeling results was carried out using in situ experiments employing the following: optical and scanning microscopy; and mechanical and X-ray methods of residual stress determination. Formtracer SV-C4500 profilograph profilometer was used in the study for simultaneous measurement of shape deviations and surface roughness. Surface topography was assessed using a Walter UHL VMM 150 V instrumental microscope. The microhardness of the hardened surface layer of the parts was evaluated on a Wolpert Group 402MVD. Results and discussion. The original methodology of structural and kinematic analysis for pre-design studies of hybrid metalworking equipment is presented. Methodological recommendations for the modernization of multi-purpose metal-cutting machine tool are developed, the implementation of which will make it possible to implement high-energy heating with high-frequency currents (HEH HFC) on a standard machine tool system and provide the formation of knowledge-intensive technological equipment with extended functionality. The innovative moment of this work is the development of hybrid metalworking equipment with numerical control and writing a unique postprocessor to it, which allows to realize all functional possibilities of this machine system and the technology of combined processing as a whole. Special tooling and tools providing all the necessary requirements for the process of surface hardening of HEH HFC were designed and manufactured. The conducted complex of works and approbation of the technology of integrated processing in real conditions in comparison with traditional methods of construction of technological process of parts manufacturing allowed to obtain the following results: increase in the productivity of processing by 1.9 times; exclusion of possibility of scrap occurrence at finishing grinding; reduction in auxiliary and preparatory-tasking time; and reduction in inter-operational parts backlogs.

INVESTIGATIONS ON THE MACHINABILITY CHARACTERISTICS OF Al–Zn(5.4)–Mg(2.4)–Cu(1.4) ALLOY COMPOSITE USING TOPSIS APPROACH

In this research, stir casting was used to create the aluminium alloy (AA7075) composite filled with 10[Formula: see text]wt.% zirconia (ZrO2) particles as reinforcement. Die sinking electric discharge machining (EDM) was used to examine the machining characteristics of the proposed composite. The machining experiments were executed in accordance with the [Formula: see text] orthogonal layout. Here, the material removal rate (MRR) and surface roughness (SR) were taken into account as the output responses, and the discharge current ([Formula: see text]), pulse on-time ([Formula: see text]), and pulse off-time ([Formula: see text]) were taken as the machining parameters. To determine the optimal parameter conditions for the output responses, the technique for order preference by similarity to ideal solution (TOPSIS) approach was applied. According to the experimental findings, the optimum settings of the parameters are determined at 15[Formula: see text]amps of ‘[Formula: see text]’, 750[Formula: see text][Formula: see text]s of ‘[Formula: see text]’ and 50[Formula: see text][Formula: see text]s of ‘[Formula: see text]’. ANOVA results stated that ‘[Formula: see text]’ has the most notable factor with a contribution of 90.85%. The interaction effect of parameters on the responses was shown by the contour plots. The confirmatory experiment was finally conducted at the optimum machining parameter settings, and it was found that the error only occurred in 8.4%.