Surface Integrity Research Articles

Smart Temperature Monitoring System for Machining Process Using Internet of Things

Outer surface integrity must be maintained throughout the machining process during the production of metal parts, which need the ability to monitor temperatures in real time. Changes in temperature during the machining process lead to changes in the behavior of the product after work is completed.To achieve quality and productivity criteria, the metal parts manufacturing process requires a continuous and precise temperature measuring and monitoring system by using IOT. An intelligent temperature measurement can be used during machining processes on conventional, non-conventional, and computer numerical control (CNC) machines. This paper presents a performance analysis of a temperature measuring system for machining process applications via Arduino IDE. In this proposal, a temperature monitoring system based on Arduino is used. The system would utilize an: MLX90614 infrared thermometer sensor” to measure the temperature of the workpiece during machining processes. The methodology's aim is to use the smart manufacturing model to measure and monitor the arising temperatures throughout the machining process in order to build a new tool path rapidly and efficiently. The placement of a non-contact infrared “MLX90614” temperature sensor allowed measuring of the average cutting temperature as well as the maximum cutting temperature. The data acquisition process was carried out using the “Xampp” Control Panel software, which communicated with the ESP32 “microcontroller” board using the Arduino IDE program. Experiments were carried out, so that the temperature of the cutting, which was measured, was recorded, and the results of the experiments were analyzed. Index Terms: Smart Manufacturing, Internet of Things, MLX90614 Infrared Temperature Sensor, Machining Parameters.

Study on the surface integrity of ultrasonic cavitation-assisted WEDM-LS under Rayleigh-Plesset model

Study on the surface integrity of ultrasonic cavitation-assisted WEDM-LS under Rayleigh-Plesset model

Surface Damage by Physical Cleans during Semiconductors Manufacturing

This paper investigates surface damage caused by physical cleaning processes during semiconductor manufacturing. The study focuses on various materials, including FDSOI wafers and polymer films, subjected to high-velocity sprays and cryogenic cleans. Thanks to the supplier process performances and quality control, FDSOI films do not present any specific concern linked with this failure mode. This latter can be observed on whatever films exposed to aggressive physical cleans and the wafers are cleverly used as a test vehicle to evidence surface defects with a revelation method using a wet etchant. It enables the detection of nano-cracks and other damages. Same defects are observed in bulk silicon wafers, and solutions exist to avoid these damages. Different spray types are compared, highlighting the impact of droplet energy distribution on surface integrity. Additionally, a direct characterization method using polymer films is developed to assess physical cleaning damage. The findings emphasize the importance of optimizing cleaning processes to balance defect removal efficiency and surface preservation. Emerging cleaning solutions like polymer coat and peel methods are also discussed for their potential to offer high cleaning performance with minimal surface damage.

Mechatronic technological system based on CNC and intelligent mechatronic mechanism

A mechatronic technological system (MTS) has been developed. It consisting of a CNC metal-cutting machine tool and a mechatronic spindle, made on the basis of an intelligent mechatronic mechanism (IMM). The main elements of the technological system – the CNC and IMM devices – are parts of a single hierarchical, two-level control system, representing, respectively, the upper and lower control levels in this system. The upper control level – the CNC device – ensures stabilization of the kinematic parameters of machining (displacement, speed, acceleration) and their software change in accordance with the CNC control program. The lower control level – the IMM device – ensures stabilization of the power parameters of mechanical machining (cutting axial force and torque) and their software change in accordance with the technological requirements for the surface quality and the physical-and-mechanical state of the surface layer of the machined parts. At both control levels (the upper and lower ones), closed automatic control systems “by deviation” of the adjustable kinematic (upper control level) and power (lower control level) parameters of mechanical machining are functioning. Moreover, the automatic control system of the lower control level of the hierarchy in relation to a similar automatic control system of the upper control level, implements the method of automatic control “by disturbance”. This, in addition to directly ensuring surface finish and surface integrity, allows improving the quality of stabilization of kinematic cutting parameters at the upper control level. Experimental studies of MTS were carried out when machining parts from various materials (steel, polymer composite materials, superhard crystals and stones, other difficult-to-machine materials).

Innovative temperature-responsive membrane with an elastic interface for biofouling mitigation in industrial circulating cooling water treatment

To address the issues of scaling caused by heat and water evaporation in regard to circulating cooling water (CCW), TFC membrane filtration systems have been increasingly considered for terminal treatment processes because of their excellent separation performance. However, membrane biofouling phenomenon significantly hinders the widespread utilization of TFC membranes. In this study, to harness the thermal phenomenon of CCW and establish a stable and durable multifunctional antibiofouling layer, temperature-responsive Pnipam and the spectral antibacterial agent Ag were organically incorporated into commercially available TFC membranes. Biological experimental findings demonstrated that above the lower critical solution temperature (LCST), the contraction of Pnipam molecular chains facilitated the inactivation of bacteria by the antibacterial agent, resulting in an impressive sterilization efficiency of up to 99 %. XDLVO analysis revealed that below the LCST, the establishment of a hydration layer on the functional interface resulted in the creation of elevated energy barriers, effectively impeding bacterial adhesion to the membrane surface. Consequently, a high bacterial release rate of 98.4 % was achieved on the low-temperature surface. The alterations in the functional membrane surface conformation induced by temperature variations further amplified the separation between the pollutants and the membrane, creating an enhanced "elastic interface." This efficient and straightforward cleaning procedure mitigated the formation of irreversible fouling without compromising the integrity of the membrane surface. This study presents a deliberately engineered thermoresponsive antibiofouling membrane interface to address the issue of membrane fouling in membrane-based CCW treatment systems while shedding new light on the mechanisms of "inactivation" and "defense."

Calcium phosphate complex of recombinant human thrombomodulin promote bone formation in interbody fusion.

Interbody fusion is an orthopedic surgical procedure to connect two adjacent vertebrae in patients suffering from spinal disc disease. The combination of synthetic bone grafts with protein-based drugs is an intriguing approach to stimulate interbody bone growth, specifically in patients exhibiting restricted bone progression. Recombinant human thrombomodulin (rhTM), a novel protein drug characterized by its superior stability and potency, shows promise in enhancing bone formation. A composite bone graft, termed CaP-rhTM, has been synthesized, combining calcium phosphate (CaP) microparticles as a delivery vehicle for rhTM to facilitate interbody fusion. In vitro studies have demonstrated that rhTM significantly promotes the proliferation and maturation of preosteoblasts at nanogram dosage, while exerting minimal impact on osteosarcoma cell growth. The expression levels of mature osteoblast markers, including osteocalcin, osteopontin, alkaline phosphatase, and calcium deposition were also enhanced by rhTM. In rat caudal disc model of interbody fusion, CaP-rhTM with 800 ng of drug doaeage was implanted along with a polylactic acid (PLA) cage, to ensure structural stability within the intervertebral space. Microcomputed tomography analyses revealed that from 8 to 24 weeks, CaP-rhTM substantially improves both bone volume and trabecular architecture, in addition to the textural integrity of bony endplate surfaces. Histological examination confirmed the formation of a continuous bone bridge connecting adjacent vertebrae. Furthermore, biomechanical assessment via three-point bending tests indicated an improved bone quality of the fused disc. This study has demostrated that rhTM exhibits considerable potential in promoting osteogenesis. The use of CaP-rhTM has also shown significant improvements in promoting interbody fusion.

Surface Integrity of Austenitic Manganese Alloys Hard Layers after Cavitation Erosion

Surface Integrity of Austenitic Manganese Alloys Hard Layers after Cavitation Erosion

Mechanism of three-body abrasive grain grinding on GaN textured surfaces under uniform acceleration and variable depth

In this study, molecular dynamics (MD) was used to simulate the three-body grinding process on the textured surfaces of gallium nitride (GaN) and to investigate the effect of the processing parameters during the grinding process on the quality of the process and the removal mechanism of the material. The results show that the friction coefficient, normal force, tangential force, grinding temperature and potential energy increase with the increase of the accelerated interval segment, while the stress, subsurface damage depth and dislocation length decrease. Overall, higher speed value classes in the GaN grinding process are favorable for improving the surface finish quality. In addition, under the conditions of variable depth machining, with the increase of rising speed, the coefficient of friction, the tangential force, the normal force, the potential energy increase, the grinding temperature increases, the stress decreases, and the subsurface damage of the workpiece and the nucleation of dislocations are also significantly reduced, and the surface finish quality and the surface integrity of the workpiece are improved. The textured surfaces is an innovation in GaN processing.

Research on SiC/Al laser-assisted nano-cutting based on molecular dynamics simulation

The laser-assisted nano-cutting process of SiC/Al was investigated using molecular dynamics simulation. The study focused on the effects of temperature, cutting depth, cutting speed, tool rake angle, and particle size on cutting force, workpiece materials pile-up, von Mises stress, and dislocation. The dislocation strengthening was found during SiC/Al laser-assisted nano cutting. Additionally, the results indicated that the thermal softening effect is more evident with the increase in temperature, resulting in smaller tangential force and normal force but with a consequent increase in the coefficient of friction and the number of stacked atoms. The study also explored the influence of cutting force and cutting temperature by the process parameters and investigated the role of strain rate and hardening effect in the cutting process. These results enhance the understanding of material removal and damage mechanisms during laser-assisted cutting and demonstrate that lasers can provide a potential technology to improve surface integrity and processing efficiency.

Exploring surface integrity: Experimental investigation into abrasive waterjet deep hole drilling on ss 316L for biomedical applications

Precision drilling of difficult-to-cut materials with exceptional surface integrity is a crucial factor in producing advanced manufactured components in industries like aviation, automotive, defense, electronic, and medical devices. More specifically, deep hole drilling enables precise customization of prostheses, improving patient comfort and functionality. Abrasive waterjet deep hole drilling has become a vital drilling technique in many industries due to its adaptability and effectiveness in drilling intricate shapes on hard-to-cut materials. The interplay between process parameters and surface finish underscores the need for systematic investigation to enhance drilling efficiency and quality. In this research, an attempt has been made to explore the influence of abrasive waterjet deep hole process parameters viz water pressure and standoff distance on the surface integrity of the drilled holes for biomedical applications. A surface roughness tester has been used to evaluate surface roughness at three distinctive places, namely the top, middle, and bottom of the drilled holes. The investigation showed that surface roughness at the top of the holes is less as compared to the middle and bottom of the holes. The average surface roughness along the depth of the drilled holes is greatly influenced by water pressure. Additionally, the morphology of the drilled holes has been studied using a scanning electron microscope (SEM). SEM images revealed that the top surface of the drilled holes is free from defects.

Notches and Fatigue on Aircraft-Grade Aluminium Alloys.

The influence of notches and fatigue on the ultimate tensile strength and elongation at break of aluminium alloys (2024-T3, 6061-T4, 6061-T4 uncoated, 6061-T6 uncoated, 7075-T0, and 7076-T6) is presented in this study. A total of 120 specimens were used. On all specimens, notches were made using a CNC machine, with 60 of them subjected to low-cycle fatigue (LCF) before undergoing the tensile test. Based on the statistical examination of the measured data, mathematical prediction models have been established. Compared to their unscratched counterparts, the results indicate a significant decrease in the UTS and elongation at break for both notched and notched-fatigued specimens. The LCF pre-treatment contributes to the negative impacts of the notches, resulting in reduced values for the UTS and elongation at break, thus concluding that surface integrity is critical for maintaining the structural strength of aircraft components.

Optimizing the diamond wire sawing of polycrystalline silicon: An experimental approach

This study aims to determine the optimized cutting conditions for diamond wire sawing of polycrystalline silicon (poly-Si) wafers using a laboratory machine-tool that employs continuous cutting movement and reach cutting conditions similar to those in the industry. The experimental cutting was carried out following a central composite design, varying the wire cutting speed (vc) and feed rate (vf). A response surface methodology was employed to find the optimized cutting conditions for minimum surface roughness and subsurface micro-crack depth of the as-sawn poly-Si wafer. The results showed that the as-sawn poly-Si exhibited ductile scratches and fragile fractures in its surface morphology, with high vc and low vf resulting in a smooth surface. The response surfaces indicated that increasing vf led to increased Ra and Rq values, while increasing vc reduced them. Median micro-cracks were slightly inclined in the subsurface region, with the response surface indicating that their depth reduced with increasing vc and decreasing vf. The vf/vc ratio significantly affected surface integrity, with a lower vf/vc ratio being more suitable for reaching a smoother surface and shallower subsurface damage. The following material removal mechanisms was identified: optimal ductile region, ductile-to-brittle transition, brittle-ductile mixture region, and brittle region. Simulations using the response surface models indicated minimum values of Ra = 0.35 μm, Rq = 0.48 μm and SSD = 3.29 μm. Thus, this study provides a processing parameter window for diamond wire sawing of poly-Si wafers, which could be useful for both the photovoltaic and microelectronic industries.

Microplastic-Related Leachate from Recycled Rubber Tiles: The Role of TiO2 Protective Coating

The extensive global use of rubber results in significant microplastic pollution from the release of tire wear particles and microplastic leachate, impacting the environment, human health, and ecosystems. Waste tires are normally recycled and used for the production of new products, such as rubber tiles. The presented study aims to show the possibility of further decrease in the negative environmental impact of materials based on recycled rubber. This paper presents the modification of rubber tiles with a titanium dioxide (TiO2) coating, focusing on surface integrity, rubber particle wear release, and the consequent environmental impact of leachate release. Both reference and modified rubber tiles were subjected to artificial accelerated aging in a solar simulator for 4, 6, and 8 weeks, followed by an abrasion test. The carbonyl index was calculated from FTIR characterization after each time frame to indicate the degradation of organic compounds and chemical changes caused by UV exposure. A 24 h leaching test with a liquid-to-sample ratio of 1:20 was performed on both rubber tile samples prior to and after 8 weeks of aging along with the aged wear particles for the purpose of the non-target screening of released organic leachate by LC/MS QTOF. The results of carbonyl indices showed that the TiO2 coating contributes to the stabilization of polymer degradation and, to a certain extent, reduces the leaching of organic compounds, such as phthalates. However, the increased wear and release of rubber particles and the subsequent degradation of organic leachates require further in-depth research.

Deformation mechanism of Ni-based single crystal superalloy under ultrasonic surface rolling and subsequent thermal exposure

In present work, ultrasonic surface rolling (USR) is applied to DD6 Ni-based single crystal (NBSC) superalloys, and the thermal relaxation behavior of the pre-treated alloys are investigated at 650 °C. Combined with mechanical properties, the plastic deformation and recovery mechanisms of the hardened layers are revealed in detail. Results show that compressive residual stress amplitude of 1163 MPa, 75.1 % improvement of surface nano-hardness and 83.02 % reduction on surface roughness are achieved by USR. Both deformed layer thickness and slip density progressively increases with USR cycles, where initial octahedron {111}<110> slips transform to a mixture of octahedron {111}<110> and dodecahedron {111}<112> slips. Meanwhile, shear step length expansions form γ′ segment/γ terminal interface with superlattice extrinsic stacking fault (SESF) on 1¯11, which may have inferior energy threshold for γ dislocation invasions than primary ones through shortening mean free path. Also, this drives γ′/γ solute mingling to induce tortuous interfaces. While dislocation proliferation dominates γ channel hardening, the γ′ hardening derives from planar fault strengthening and net system energy augmentation. During thermal exposure, surface integrities of USRed DD6 are strongly degraded, attributable to slip trace elimination and local γ′ coarsening. Thermal exposure further compels the γ dislocation to migrate towards γ′ segment across γ′ segment/γ terminal interface. Then, they are probably consumed to motivate solutes to phase boundary to reshape the γ′ morphologies through interface rearrangements under the assistance of γ dislocation network. The orientation transformation of SESF on 1¯11 to 010 and the mixture of SESF and superlattice intrinsic stacking fault on 1¯11 are thought to be possible manipulated mechanisms for γ′ coarsening, significant impairing the work hardening of alloy due to interfacial coherency deterioration. This paper could provide guidance for USR strengthening designs of NBSC.

Enhancing fatigue performance of AA6063-T6 fasteners through novel electromagnetic cold expansion using a double-frequency discharge

Non-contact electromagnetic cold expansion process (EMCE) represents a highly promising way to enhance the fatigue performance of fasteners. However, within the current technological framework, the necessity for dual power supplies and an accurate discharge control system has constrained the development and application of this technique. To address this, a novel EMCE process utilizing a double-frequency discharge is proposed. This process is accompanied by the development of an electromagnetic system with only one set of power supply to generate a current composed of a gradual-ascending and rapid-descending stage. This current induces a significant radially outward Lorentz force, facilitating hole expansion and introducing residual compressive stress around the hole, thus increasing the fatigue life of the fasteners. The experimental results demonstrate a remarkable enhancement in fatigue life for samples treated with the EMCE process when compared to untreated ones, showing an impressive 6.8-fold, 4.9-fold, and 1.6-fold increase at stress loads of 120 MPa, 130 MPa, and 150 MPa, respectively. Microstructural analysis reveals that the processed components exhibit favorable surface integrity, and there is no significant grain refinement near the hole. Moreover, it is found that there existed optimal current waveform to maximize fatigue life. These findings hold significance in understanding the EMCE process and advancing its practical applicability.

Surface characteristics of maraging steel during electropolishing as a function of polishing time

ABSTRACT Thermal-based machining process like EDM, Laser-assisted additive manufacturing process degrades the surface integrity of the component. Therefore, a post-polishing method is required to improve the surface integrity as well as the performance of the component. A gyroscope, made of maraging steel, fabricated by EDM, is utilised in space industry and has poor surface integrity, which affects its performance. Thus, electropolishing (EP), a non-conventional polishing process, is used for the above said problem as it possesses several advantages over other polishing methods. There are very few literatures available for EP of maraging steel. The present manuscript is the preliminary analysis for the electrolyte (Ortho-phosphoric acid, sulphuric acid and hydrochloric acid) and its effect on maraging steel with respect to time. The surface characteristics such as surface roughness and surface reflectivity, along with surface elemental composition, have been evaluated. With increase in time, maximum improvement in surface roughness and surface reflectivity is 61.23% and 70%, respectively. It can be concluded that the selected electrolyte gives a promising improvement in the surface characteristics of maraging steel.

A framework toward fatigue life modeling of machining process verified in burnishing

In the present work a multiscale model was developed to predict fatigue lives of Inconel 718 after a machining process. The model captures the effects of surface integrity like residual stress, microstructure, hardness and roughness. Within this holistic predictive model, firstly burnishing process factors (viz static force, feed rate, spindle speed and pass number) are correlated to surface integrity aspects. Herein, residual stress is modeled using theory of incremental plasticity; also grain size and hardness were correlated to process factors through dislocation density evolution. In order to model the surface roughness, the Z-map approach considering the work hardening of the surface layers was utilized. The foresaid developed models of surface integrity aspects were utilized to predict the fatigue life using Navaro-Rios crack propagation together with Chen’s crack initiation models. Thus, a novel holistic model correlating machining parameters directly to fatigue life has been developed through this hybrid approach. The developed models of fatigue life and surface integrity aspects were then confirmed by series of burnishing experiments on Inconel 718. Later, the confirmed model was utilized to identify the parametric influence of burnishing process on variation of fatigue life where the results were justified using variation of surface integrity factors. Through this developed model, it was found that burnishing setting of 1000 N static force, 0.05 mm/rev feed rate, 300RPM spindle speed and 2 pass number results in improvement of HCF, MCF and LCF of 242 %, 184 % and 212 % where the obtained results from the developed framework were compatible well with experimental values.

Study on the fatigue performance and Residual Stress of subsurface fluid flow of 2519a aluminum alloy based on water jet peening

In this study, the influence mechanism of water jet (WJ) strengthening on the surface integrity and fatigue properties of 2519 aluminum alloy was investigated by using finite element software Abaqus 2023 and fatigue analysis software Fe-safe. The effects of jet velocity and transverse velocity on the development of surface roughness and residual stress in different strengthening stages were studied, and the fatigue properties of WJ strengthened samples were analyzed by Fe-safe fatigue software. Finally, the fatigue life and fracture morphology of WJ strengthened specimens were analyzed by fatigue test, and the accuracy of finite element analysis was verified. Results indicate that surface roughness post-WJ enhancement displays a “W” shaped distribution, positively correlated with jet velocity. Conversely, increased roughness negatively correlates with higher traverse speeds, with optimal values recorded between 400 and 600 mm/min at WJ-290 mm/s, ranging from 1.10322 to 1.41167 μm. Additionally, the study reveals that maximum residual compressive stress during the WJ-Ip phase correlates positively with jet velocity, peaking at 302 MPa for WJ-290 mm/s. The research also notes that while higher jet velocities enhance residual compressive stress, they simultaneously elevate surface roughness, potentially introducing damage and increasing the variability of stress magnitudes. The study underscores the necessity of meticulously calibrating WJ parameters to enhance surface quality effectively while minimizing adverse effects. This balance is critical to optimizing the treatment process and achieving desired material properties.

Influence of milling-finishing-shot peening hybrid machining on the surface integrity and fatigue performance of TC11 titanium integral impeller

Influence of milling-finishing-shot peening hybrid machining on the surface integrity and fatigue performance of TC11 titanium integral impeller

Parameter Optimization of a Surface Mechanical Rolling Treatment Process to Improve the Surface Integrity and Fatigue Property of FV520B Steel by Machine Learning.

Surface integrity is a critical factor that affects the fatigue resistance of materials. A surface mechanical rolling treatment (SMRT) process can effectively improve the surface integrity of the material, thus enhancing the fatigue property. In this paper, an analysis of variance (ANOVA) and signal-to-noise ratio (SNR) are performed by orthogonal experimental design with SMRT parameters as variables and surface integrity indicators as optimization objectives, and the support vector machine-active learning (SVM-AL) model is proposed based on machine learning theory. The entire model includes three rounds of AL processes. In each round of the AL process, the SMRT parameters with relative average deviation and high output values from cross-validation are selected for the additional experimental supplement. The results show that the prediction accuracy and generalization ability of the SVM-AL model are significantly improved compared to the support vector machine (SVM) model. A fatigue test was also carried out, and the fatigue property of the SMRT specimens predicted by the SVM-AL model is also higher than that of the other specimens.