Surface Roughness Of Steel Research Articles

Experimental Investigation on Material Removal Rate, Surface Roughness of Stainless Steel 306 by EDM

Experimental Investigation on Material Removal Rate, Surface Roughness of Stainless Steel 306 by EDM

Hydrophobic and Superhydrophobic Bio-Based Nano-Magnetic Epoxy Composites as Organic Coating of Steel

New epoxy resin hardeners were prepared from the reaction of p-nonylphenol and cardanol glycidylether with pentaethylenehexamine (PEHA) to produce hydrophobic polyamines. They were used as capping to produce superhydrophobic magnetite nanoparticles (Fe3O4 NPs). The chemical structures, thermal stability, morphologies, and particle sizes diameters were evaluated to confirm the hydrophobicity of dicardanoxy (DCHI) and dinonylphenoxy (HPHI) polyamines. The curing exothermic reaction of bisphenol A diglycidyl ether (DGEB) epoxy resin with DCHI, HPHI, or their Fe3O4 NPs was investigated by dynamic mechanical analyzer and differential scanning calorimetry. The cured epoxy networks crosslinking densities, storage modulus, and glass transition temperatures were determined and correlated to epoxy networks chemical compositions. DGEB/DCHI and DGEB/HPHI with their stoichiometric ratio embedded with their Fe3O4 NPs were applied on the rough steel surface to produce hydrophobic and superhydrophobic epoxy coatings. The wetting characteristics of the cured epoxy nanocomposites were evaluated from seawater contact angle (WCA) measurements to prove the formation of superhydrophobic coatings in the presence of DCHI-Fe3O4 NPs having WCA > 150°. The excellent adhesion, mechanical, and anti-corrosion performances using DGEB/DCHI and DGEB/HPHI epoxy nanocomposites were obtained on the steel surfaces in the presence of seawater corrosive environment.

The effect of twist drill angle and spindle speed on surface roughness in S45C steel drilling process

The purpose of this research is to determine the effect of twist drill angle variations and spindle rotational speed on the surface roughness of S45C steel in the drilling process. The method used in this research is the experimental method. The independent variables used in this study are variations in twist drill angle (118°, 122°, 125°) and spindle rotational speed variations (1036 rpm, 1340 rpm, 1630 rpm). The dependent variable used is the result of surface roughness in S45C steel. While the control variable used is a feed rate of 0.18 mm/round. The results showed the highest surface roughness was obtained at 125° twist drill angle variation and spindle rotational speed of 1630 rpm with a roughness value of 8.590 µm, while the lowest surface roughness value was obtained at 118° twist drill angle variation and spindle rotational speed of 1036 rpm with a roughness value of 2.898 µm. This research can be developed to find standards from other aspects that affect the results of the drilling process.

Effect of cutting conditions on power demand and surface roughness through sustainable turning of mild carbon steel

Sustainable turning is a lathe machining process to carry out production in particular by paying attention to the sustainability of machinery without reducing production output. The machining process is done by optimizing the turning process parameters when carrying out the cutting process on medium carbon steel. Some parameters affect the lathe process, including speed, feed rate, and cooling. The purpose of this study was to determine the machining conditions in order to optimize the electric power consumption and surface roughness of the medium carbon steel turning process. The research method used was experimental and analysed using the ANOVA method. From the results of the research, it was concluded that the minimum electricity consumption was obtained in the process of turning steel St 42 without cooling with a speed of 237 rpm and a feeding of 0.157 mm/rev. The lower surface roughness was obtained in the turning process of St 60 steel with a rotation speed of 840 rpm and a feed rate of 0.157 mm/rev. The results of data analysis using ANOVA analysis method to get optimal conditions in order to minimum power demand and low surface roughness at 425 rpm of speed and 0.052 mm/rev of feed rate.

Measurement and inspection of electrical discharge machined steel surfaces using deep neural networks

We propose an industrial measurement and inspection system for steel workpieces eroded by electrical discharge machining, which uses deep neural networks for surface roughness estimation and defect detection. Specifically, a convolutional neural network (CNN) is used as a regressor in order to obtain steel surface roughness and a CNN based on spatial pooling pyramid is applied for defect classification. In addition, a new method for the region of interest selection based on morphological reconstruction and mean shift filtering is proposed for defect detection and localization. The regressor and classifier based on deep neural networks proposed here outperform state-of-the-art methods using handcrafted feature extraction. We achieve a mean absolute percentage error of 7.32% on roughness estimation; on defect detection, our approach yields an accuracy of 97.26% and an area under the ROC curve metric of 99.09%.

Determination of coefficients of friction for laminated veneer lumber on steel under high pressure loads

In this study, static coefficients of friction for laminated veneer lumber on steel surfaces were determined experimentally. The focus was on the frictional behaviors at different pressure levels, which were studied in combination with other influencing parameters: fiber orientation, moisture content, and surface roughness. Coefficients of friction were obtained as 0.10–0.30 for a smooth steel surface and as high as 0.80 for a rough steel surface. Pressure influenced the measured coefficients of friction, and lower normal pressures yielded higher coefficients. The influence of fiber angle was observed to be moderate, although clearly detectable, thereby resulting in a higher coefficient of friction when sliding perpendicular rather than parallel to the grain. Moist specimens contained higher coefficients of friction than oven-dry specimens. The results provide realistic values for practical applications, particularly for use as input parameters of numerical simulations where the role of friction is often wrongfully considered.

Materials Testing

This paper presents the effect of cutting tool, cutting speed and feed rate on the flank wear and surface roughness of austenitic stainless steel (AISI 304) during wet turning. Turning tests were designed based on the Taguchi method (L18). An orthogonal array, the signal-to-noise ratio (S/N) and the ANOVA were used to investigate the machinability of AISI 304 stainless steel with PVD and CVD coated tungsten carbide inserts. As a result of ANOVA, it was found that the feed rate was the most effective parameter on both flank wear and surface roughness.

Taguchi optimization of minimum quantity lubrication turning of AISI-4320 steel using biochar nanofluid

In this research work, the effect of minimum quantity lubrication (MQL) parameters on the material removal rate and surface roughness of AISI-4320 steel using biochar nanofluid in turning process was studied. The main aim of this present work was to optimize the process parameters of MQL turning process using Taguchi method. The turning process outputs such as material removal rate and surface roughness were measured and analyzed using gray relational grades to determine the process efficiency using biochar nanofluid. The study was conducted using Taguchi L9 orthogonal array followed by grey relational method. According to the analysis, the nanofluid concentration in minimum quantity lubrication was the most influencing process parameter with the lowest fluid flow rate to produce the highest material removal rate of 58.312 mm3/s and low surface roughness of 3.236 μm. The machining process parameter levels such as A3B1C3 are found to be the promising process variable levels, where the highest material removal rate and lower surface roughness were produced. The SEM micrographs of the tool tip show a lower tool wear for machining with nanofluid of 2 wt.% biochar.

Direct and Indirect Evidence of the Microbially Induced Pitting Corrosion of Steel Structures in Humid Environments

Corrosion is a severe problem for steel structures in humid environments. In particular, humidity usually triggers the surface adhesion of microorganisms, leading to microbiologically induced corrosion. This study aims to explore the effect of bacterial biofilm formation on the pitting corrosion of stainless steel. This research uses electrochemical methods to obtain indirect evidence of the pitting corrosion of steel. In addition, in order to obtain direct evidence of the pitting corrosion of stainless steel, field emission scanning electron microscopy (FESEM) and atomic force microscopy (AFM) were used to characterize the dimensional morphology of the stainless steel after pitting. It was shown that the bacterial adhesion increased with the pH and temperature, which significantly increased the surface roughness of the stainless steel. Electrochemical analysis revealed that the formation of biofilm greatly destroyed the oxide film of 304 SS and accelerated the corrosion of stainless steel by forming an oxygen concentration battery. SEM and AFM analyses showed cracks and dislocations on the surface of stainless steel underneath the attached bacteria, which suggested a direct role of biofilm in corrosion induction. The results presented here show that the bacterial biofilm formation on the steel surfaces significantly accelerated the corrosion and affected the pitting corrosion process of the steel structure.

Optimization of flank wear and surface roughness during turning of AISI 304 stainless steel using the Taguchi method

Abstract This paper presents the effect of cutting tool, cutting speed and feed rate on the flank wear and surface roughness of austenitic stainless steel (AISI 304) during wet turning. Turning tests were designed based on the Taguchi method (L18). An orthogonal array, the signal-to-noise ratio (S/N) and the ANOVA were used to investigate the machinability of AISI 304 stainless steel with PVD and CVD coated tungsten carbide inserts. As a result of ANOVA, it was found that the feed rate was the most effective parameter on both flank wear and surface roughness.

Influence of lubrication, tool steel composition, and topography on the high temperature tribological behaviour of aluminium

The use of high strength aluminium alloys, such as 6XXX and 7XXX series, is continuously increasing for automotive applications in view of their good strength-to-weight ratio. Their formability at room temperature is limited and they are thus often formed at high temperatures to enable production of complex geometries. Critical challenges during hot forming of aluminium are the occurrence of severe adhesion and material transfer onto the forming tools. This negatively affects the tool life and the quality of the produced parts. In general, the main mechanisms involved in the occurrence of material transfer of aluminium alloys at high temperature are still not clearly understood. Therefore, this study is focussed on understanding of the friction and wear behaviour during interaction of Al6016 alloy and three different tool steels in as-received and polished state. The tribotests were carried out under dry and lubricated conditions, with two distinct lubricants, using a reciprocating friction and wear tester. The worn surfaces were analysed using scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS). The results showed a high dependence of friction and wear behaviour on the tool steel roughness as well as on the stability of the lubricant films. Tribolayers were found to develop in the contact zone and their capacity to improve the tribological behaviour is seen to be drastically impacted by the surface roughness of the tool steel. When the tribolayers failed, severe adhesion took place and led to high and unstable friction as well as material transfer to the tool steel.

Optimization of flank wear and surface roughness during turning of AISI 304 stainless steel using the Taguchi method

AbstractThis paper presents the effect of cutting tool, cutting speed and feed rate on the flank wear and surface roughness of austenitic stainless steel (AISI 304) during wet turning. Turning tests were designed based on the Taguchi method (L18). An orthogonal array, the signal-to-noise ratio (S/N) and the ANOVA were used to investigate the machinability of AISI 304 stainless steel with PVD and CVD coated tungsten carbide inserts. As a result of ANOVA, it was found that the feed rate was the most effective parameter on both flank wear and surface roughness.

Influence of Polarity of Electro Discharge Machine (EDM) on Surface Roughness (SR) and Metal Removal Rate (MRR) of Low Carbon Steel

Electro discharge machining (EDM) is one of a thermal process that is used for remove of metal from the workpiece by spark erosion. The work of this machine depends on multiple variables. One of the more influential variants on this machine is the change of polarity and the use of this variable is not wide and the research depends on the polarity of the machinist. Essentially, the polarity of the tool (electrode) is positive and the workpiece is negative, this polarity can be reversed. This paper focuses on the influence of changing the polarity (positive and negative) on the surface roughness and metal removal rate by using different parameters (current, voltages, polarity and Ton). Experiments show that the positive electrode gives (best surface roughness = 1.56 µm when the current = 5 Am and Ton = 5.5 µs) and (best metal removal rate = 0.0180 g/min when the current = 8 Am and Ton = 25 µs). Negative electrode gives (best surface roughness = 0.46 µm when the current = 5 Am and Ton = 5.5 µs) and (best metal removal rate = 0.00291 g/min when the current = 8 Am and Ton = 25 µs).

The Effect of Surface Roughness of Low Carbon Steel by Heat Treatment in Turning Operation

This research focuses on enhancing the surface roughness of low carbon steel by heat treatment of low carbon steel in turning operation. Heat treatment is mainly used to improve the mechanical properties of materials. Two sets of specimens used during the experiment where each has 5 pieces of mild steel that heat-treated of two-level of temperatures of 650 oC and 900oC. After the heating process of all specimens, it will be exposed to different coolant media which are quenching, normalizing and annealing. A carbide single-point tool, one level of cutting parameters selected as one level of cutting speed and depth of cut and two levels of feed rate used during this research. The results show that specimen quenched by oil bath measures the highest value of the surface roughness of 8.26 µm at 900oC and machined with a feed rate of 0.113 mm. While quenched water specimens show less surface roughness of 4.91µm at 650oC in the same feed rate.

Effect of Surface Roughness on Crystal Size of Manganese Phosphate Coating of Carbon Steel.

In this study, the correlation between surface roughness of carbon steel and crystal size of manganese phosphate coatings has been investigated. The microstructure and surface morphology of the coatings were analyzed by SEM, XRD. The surface roughness test was carried out in order to calculate Ra value by atomic force microscopy (AFM). Also, the tribology property of manganese phosphate coating was tested by ball-on disk. XRD showed that (Mn,Fe)5H₂(PO₄)₄·4H₂O in manganese phosphate coating layer was formed by the chemical reaction between manganese phosphate and elements in carbon steel. Also, (Mn,Fe)5H₂(PO₄)₄ · 4H₂O was observed to be formed in all manganese phosphate conversion coating. With regard to the effects of surface roughness on manganese phosphate coatings, it can be seen that there is an increase of the crystal size on manganese phosphate coating as the surface roughness of carbon steel decreased. The increase of crystal size by the surface roughness had effect on the tribology property and electrochemical property. It was approved that friction coefficient of manganese phosphate coating is remarkably improved as the surface roughness of carbon steel become rough.

Influence of Turning Parameters on Turning Performance of Ultra-High Strength Steel

In order to improve the turning process performance of ultra-high strength steel in aircraft landing gear, the effects of different cutting parameters on cutting force and surface roughness of A100 steel and 300M steel were studied by orthogonal test. Multivariate linear regression analysis of cutting parameters was carried out, and empirical formulas of three-dimensional cutting force and surface roughness were established. The results show that when cutting A100 steel, feed has the greatest impact on cutting force. When turning 300M steel, back cutting depth has the greatest impact on cutting force. For surface roughness, back cutting depth has the greatest impact on the two materials, and spindle speed has the smallest.

Effect of organic friction modifiers on lubrication of PEEK-steel contact

The rapid adoption of the advantageous PEEK/steel pairing in many tribological applications has prompted intense research to optimize its lubrication. Thus, the role of organic friction modifiers (OFMs) in improving the lubrication of PEEK-steel contacts has been studied and their mechanism explained. Their effect on friction and wear depends on the type of contact motion (i.e. sliding or sliding-rolling) and the steel surface roughness. N-oleoyl sarcosine had a significant effect on tribological properties due to its ability to absorb strongly on both materials, inhibit the formation of PEEK transfer films on steel and thus exert either a positive or negative effect depending on the test conditions.

Optimization of Surface Roughness of EN-36 Alloy Steel on CNC Turning Machine using Box Behnken Method under RSM

Optimization of Surface Roughness of EN-36 Alloy Steel on CNC Turning Machine using Box Behnken Method under RSM

Wear behavior of B4C reinforced Al 6063 matrix composite electrodes fabricated by stir casting method

The objective of the present study was to predict the surface topological characteristics of Al–B4C composite electrodes and oil hardened, non-shrinking (OHNS) die steel in the electrical discharge machining (EDM) process. The surface characteristics of the composite electrodes were evaluated using a scanning electron microscopy (SEM) and EDAX analysis. The surface roughness and hardness of the OHNS die steel were measured using a Stylus probe and Brinell hardness tester, respectively. The composite electrodes were prepared with Al 6063 and B4C materials. In the stir casting process, the two materials were mixed at the molten state at different compositions. The chemical composition of the composite electrodes were analyzed by SEM and EDAX testing. The surface roughness of the OHNS steel was measured using a Brinell hardness tester. Based on SEM and EDAX results, 92% Al 6063, 8% B4C produced the best surface roughness in OHNS die steel.

Effect of shot peening coverage on residual stress and surface roughness of 18CrNiMo7-6 steel

Shot peening is becoming a widely used surface strengthening technique for various key mechanical components for its enhanced influence on the fatigue performance. This technique allows to strengthen the mechanical properties of material via introduce a certain depth of compressive stress layer and change the surface topography. The relation of the shot peening processing parameters, the surface integrity including residual stress and the surface roughness remains a large unmet practical need. In this paper, the residual stress and surface topography obtained by various shot peening treatments were experimentally and theoretically examined. A random multi-shots peening model of a carburized roller, accounting for the initial hardness gradient and residual stress was developed. The measured residual stress and surface roughness present good agreements with the predicted results. Both the experimental and simulated results reveal that the axial and tangential residual stress components tend to be consistent after shot peening. In addition, the influence of peening coverage on detailed evolution of surface topography and residual stress is investigated. It is found that the ratio between the layer thickness of compressive stress and the critical depth of maximum stress generally lies in the regime of 3.6–4.3 after shot peening. As the coverage increases from 100% to 400%, surface roughness parameters Sa, Sq, S5z, Sku decrease, while the maximum magnitude of compressive stress fluctuates in the range of 1105∼1230 MPa. This work could act as an advisory reference for shot peening engineering practices.