Analysis Of Surface Quality Research Articles

Bisquare robust polynomial fitting method for dimple distortion minimization in surface quality analysis

In this paper, the bisquare robust polynomial fitting (BSRPF) method for surface texture features assessment was proposed. Plateau‐honed cylinder liner bronze surfaces with additionally burnished microcavities (defined as dimple, holes, and/or cavities) were taken into consideration. Analyzed details were measured with stylus (Talyscan 150) or white light interferometer (Talysurf CCI Lite) methods. It was assumed that application of commonly used (in surface contact and noncontact measurement technology) polynomial fitting procedures did not allow to extract required features; distortion of microreservoir dimples for oil consumption assessment was falsely estimated when valleys were near edge or on the edge located. Application of bisquare robust polynomial fitting method caused a minimization of microflattens of dimples irrespective of valley distribution; the biggest degree of polynomial fitting method applied, the minimal distortions of oil reservoirs were noticed. The valley size (depth and width) and valley‐to‐valley distance were also taken into account.

Enhancing the Surface Quality of Micro Titanium Alloy Specimen in WEDM Process by Adopting TGRA-Based Optimization.

The surface measures of machined titanium alloys as dental materials can be enhanced by adopting a decision-making algorithm in the machining process. The surface quality is normally characterized by more than one quality parameter. Hence, it is very important to establish multi-criteria decision making to compute the optimal process factors. In the present study, Taguchi–Grey analysis-based criteria decision making has been applied to the input process factors in the wire EDM (electric discharge machining) process. The recast layer thickness, wire wear ratio and micro hardness have been chosen to evaluate the quality measures. It was found that the wire electrode selection was the most influential factor on the quality measures in the WEDM process, due to its significance in creating spark energy. The optimal arrangement of the input process parameters has been found using the proposed approach as gap voltage (70 V), discharge current (15 A) and duty factor (0.6). It was proved that the proposed method can enhance the efficacy of the process. Utilizing the computed combination of optimal process parameters in surface quality analysis has significantly contributed to improving the quality of machining surface.

Experiments Research on Electrical Discharge Grinding Polycrystalline Diamond Tool based on Surface Quality Analysis

As the hardest material in the field of synthetic materials, polycrystalline diamond has attracted more and more attention in the field of tools, which reflects the basic characteristics of ‘high efficiency, precision and flexibility’ of modern advanced cutting technology and clean production. Electrical discharge grinding (EDG) is often used in polycrystalline diamond tools, especially in special shape, thin and fine edge cutting tools. Taking two kinds of grain size of polycrystalline diamond as the research object, taking the machining test and material test as the analysis means, this paper simply compares the surface quality of disc electrode and wire electrode machining, and studies the influence of diamond particle size, electrode polarity and electrode rotation speed on the surface quality and material removal rate of precision electrical discharge grinding polycrystalline diamond. The results show that there is no porous structure, good surface quality and no selectivity in discharge removal when using the negative polarity machining. With the increase of electrode rotation speed, the removal amount of polycrystalline diamond material increases gradually, and the surface roughness of polycrystalline diamond material decreases first, then increases. When the electrode rotation speed reaches 80 m/min, the surface roughness of the polycrystalline diamond sample reaches the minimum value, and the removal amount of polycrystalline diamond material also tends to be stable.

Surface Quality Analysis of Friction Stir Welded Joints by Using Fourier Transformation and Local Binary Patterns Algorithms

Abstract: Friction Stir Welding process is an advanced solid-state joining process which finds application in various industries like automobiles, manufacturing, aerospace and railway firms. Input parameters like tool rotational speed, welding speed, axial force and tilt angle govern the quality of Friction Stir Welded joint. Improper selection of these parameters further leads to fabrication of the joint of bad quality resulting groove edges, flash formation and various other surface defects. In the present work, a texture based analytic machine learning algorithm known as Local Binary Pattern (LBP) and Fourier transformation algorithm are used for the extraction of texture features of the Friction Stir Welded joints which are welded at a different rotational speed. It was observed that LBP algorithm can accurately detect any irregularities present on the surface of Friction Stir Welded joint and Fourier transformation method can detect the groovy edges present on the Friction Stir Welded joint. In the case study, an image based defect recognition system by using Fourier transformation method is constructed. Five types of filters i.e. Ideal Filter, Butterworth Filter, Low pass Filter, Gaussian Filter and High Pass Filter were used. The results showed that the high pass filter has more capability to detect the edges in comparison to other four filters. It was also observed that Ideal filter has a lot of distortions when compared to the Gaussian Filter and Butterworth Filter.

Research and Modelling of Surface Roughness, Cutting Forces and I-kaz Coefficients for S42C in Turning using Response Surface Methodology

This paper presents the optimization in machining processes on the cutting parameters for the S45C in turning process using the response surface method (RSM). The experimental work conducted investigates the influence of cutting parameters on statistical analysis of signals and surface quality. The paper also presents a statistical analysis of signal processing. The cutting force was measured during machining using the Kistler 9129AA dynamometer to monitor the force signals and the data was analyzed using the I-kazTM method of statistical analysis. This statistical analysis was used to assess the effect of force signals during the machining process. The RSM models for Ra and Rz, and Ideveloped with ANOVA and multiple regression equations. The models also were compared and validated with the predicted and measured of Ra and Rz values, and I-kaz coefficients. The optimal configuration of cutting parameters was observed at 200 m/min, 0.1 mm/rev and 0.521 mm with desirability of 95.9%. It is observed that the models developed are suggested to be utilized for predicting surface roughness values and I-kaz coefficients for the machining of S45C steel.

Analysis and optimization of surface quality of stainless steel miniature gears manufactured by CO2 laser cutting

This paper reports the results of investigation conducted on CO2 laser cutting of miniature gears of stainless steel 304. In this work, analysis of the effects of important laser parameters such as power, cutting speed, focal position, and gas pressure on average surface roughness (Ra) has been investigated. Stainless steel spur gears having 9.04 mm outside diameter and 4.5 mm face width have been cut using a CO2 laser system with nitrogen as assisted gas. A total of twenty nine experiments have been conducted based on BBD (Box-Behnken Design) technique of response surface methodology where aforementioned laser parameters varied at three levels each. ANOVA study found focal position as the most significant parameter. Further, the Desirability based optimization of laser parameters obtained best values of Ra- 0.43 μm at laser power- 2407 W, cutting speed- 1.25 m/min, focal position- (-) 2.4 mm, gas pressure- 12.5 bar. A scanned electron microscopy study also revealed the good surface morphology of the miniature gear machined at optimum parameters.

Analysis and optimization of surface quality while machining high strength aluminium alloy

This paper presents a systematic investigation on analysis and optimization of surface quality during turning of high strength Al 7075. In this central composite design based study, the effect of four important machining parameters such as cutting speed, feed rate, depth of cut, and tool nose radius on the surface quality characteristics namely form error i.e. cylindricity error and circularity error, and average surface roughness has been investigated. The material removal rate is also considered as an important response parameter. The analysis of variance study has been conducted to find the statistically significant parameters. The derived empirical relationships predicted the randomly generated test cases with less than 8.51%. Optimization for multiple outputs with conflicting requirements has been done using the principal component analysis and JAYA algorithm that resulted in the absolute deviation of 7.97% with average roughness- 0.64 µm, circularity error- 4.34 µm, cylindricity error- 0.365 µm, and material removal rate-28.63 cm3/min.

Comparison between different methods for experimental analysis of surface integrity in die-sinking electro-discharge machining processes

Advanced manufacturing techniques such as die-sinking electro-discharge machining have been introduced in different industries such as the naval, automotive and product manufacturing. The surface finish of the parts subjected to these processes is influenced by diverse factors related to geometrical parameters, electric circuit, lubrication system and materials. For that reason, this work is focused on the analysis of the surface morphology of machined part that can be achieved by electro-discharge machining, as a function of some of the main process parameters such as the current intensity and penetration depth. In this work, three different methods for experimental analysis of surface quality, based on the measuring of surface roughness, material profile ratio and crater diameter, were applied and compared. The experimental phase included tests with copper tools on AISI 316 stainless steel workpieces. The surface roughness and accumulated material profile were recorded using measurements made with a profilometer, and for the purpose of measuring the diameter of the craters, scanning electron microscopy technology was used. According to the results, crater diameter can be adopted as a better indicator to characterize the surface quality in electro-discharge machining, because it exhibits a clearer tendency as a function of current intensity and penetration depth.

Analysis of Dimensional Accuracy (Over Cut) and Surface Quality (Roughness) in Electrical Discharge Machining of Inconel-718 Alloy

Inconel-718 is a nickel based super alloy (difficult-to-cut material) used in aerospace industry. Analysis of machining performances viz. Over Cut (OC) & Surface Roughness (SR) for Inconel-718 through rotary Cu-pin tool electrode have been carried out. Peak current (Ip), pulse-on time (Ton), tool rotation (Nt) & hole depth (h) were used as input factors in Electrical Discharge Drilling (EDD) of Inconel-718 work-piece. Effect of input parameters on performance characteristics like OC & SR were found by Taguchi’s L9 (34) orthogonal array. It is reveals that Ip & h are most affecting factors that affects OC & SR. The Scanning Electron Microscope image was used to measure diameter of hole on work-piece after machining.

Complex taper profile machining of WC-Co composite using wire electric discharge process: analysis of geometrical accuracy, cutting rate, and surface quality

Complex profiles, comprising curved features and inclined surfaces, are an inherent attribute of tungsten carbide (WC-Co) tooling applications like dies, molds, and cutting tools. Such profiles are difficult to machine by conventional processes due to high hardness of WC-Co. Wire electric discharge machining (WEDM) is a frequently employed non-traditional machining process for producing intricate shapes and complex geometries in difficult-to-cut materials. However, this process offers its own challenges regarding machining accuracy of arced profiles such as undercutting or overcutting of material. Machining task becomes more complicated if arced profiles are to be machined at a certain taper angle. Keeping in view the stringent requirements of productivity and geometrical accuracy for WC-Co tooling, current research is focused on comprehensively evaluating the performance of WEDM process for producing complex tapered profiles in WC-Co composite. Furthermore, instead of using simple brass wire, a zinc-coated wire electrode is employed to enhance cutting rate. The impact of WEDM control variables namely, pulse-on/off time, servo voltage, and wire tension, in conjunction with workpiece taper, is studied on geometrical accuracy, cutting rate, and surface quality of complex tapered profile. Results of experimentation are analyzed using various statistical techniques. Scanning electron microscopy (SEM) and energy-dispersive X-ray (EDX) analysis are carried out for in-depth evaluation of machining results. Experimental results show that a complex tapered profile can be generated with as small as 0.16° angular error and 6-μm radial error using optimal parameter settings. Optimal settings of process parameters result into 33.3% reduction in angular error, 14.3% reduction in radial error, 12% increase in cutting speed, and 14.4% reduction in surface roughness of workpiece.

Fractal-Based Analysis of the Relation Between Surface Finish and Machine Vibration in Milling Operation

Analysis of surface quality of machined workpiece is an important issue in machining of materials. For this purpose, scientists analyze how the texture of machined surface changes due to different conditions. Machine vibration is one of the factors that highly affects the surface quality of machined surface. In this research, we analyze the relation between machine vibration and surface quality of machined workpiece. For this purpose, we employ fractal theory and analyze how the complex structure of machined surface changes with the complex structure of machine vibration signal in case of variations of machining parameters, namely, depth of cut, feed rate and spindle speed, in milling operation. Based on the results, variations of surface quality of machined workpiece are related with the variations of complexity of machine vibration signal. The method of analysis employed in this research can be applied to other machining operations in order to find the relation between machine vibration and surface quality of machined workpiece.

FRACTAL-BASED ANALYSIS OF THE EFFECT OF MACHINING PARAMETERS ON SURFACE FINISH OF WORKPIECE IN TURNING OPERATION

Analysis of workpiece surface quality is one of the major issues in manufacturing engineering. Turning operation is a famous machining operation that is widely used in machining of materials. In this research, we investigate the surface finish of machined workpiece from turning operation. For this purpose, we employ fractal theory to study the complex structure of machined workpiece’s surface in different conditions. The applied parameters include the variations of cutting depth, feed rate and spindle speed in wet and dry machining conditions. Based on the obtained results, we found the correlation between the increment of fractal dimension of machined surface and the increment of cutting depth, feed rate and spindle speed in wet machining condition. The obtained results will be discussed in relation with the complexity of machined surface. The employed method of analysis in this research can be widely applied to the analysis of the effect of different machining parameters and conditions on the surface quality of machined workpiece in case of different machining operations.

Analysis of tool wear performance and surface quality in post milling of additive manufactured 316L stainless steel

Laser additive manufacturing (LAM) technology applied to the 316L stainless steel is attracting interest in the machining industry since it can shorten the production cycle and reduce numbers of machining steps. It still needs to be machined because of the poor surface quality, so the tool wear of post milling process after LAM needs to be studied. However, there are a few studies about the tool wear in milling of laser additive manufacturing stainless steel alloy. The aim of the paper is to evaluate the tool wear performance and surface quality when post milling the 316L stainless steel under different post milling (PM) time. The tool wear behavior was investigated using different analysis techniques. 3-D surface contour profilometer was used to measure the surface roughness and observe the morphology of small area; digital optical ultra-depth microscope analysis was carried out to evaluate tool wear and broken; the wear width of the blade was an indicator of the degree of the tool wear; different post milling methods were also compared. The obtained results demonstrate that the height of the LAM parts were connected with the heat dissipation effect; there are three stages of tool wear: initial wear stage, normal processing stage, and severe broken stage; usually the down-milling is better than up-milling at the bottom surface roughness, quality and edge morphology.

Analysis of surface roughness in turning process using rotating tool with chip breaker for specific shapes of automotive transmission shafts

Abstract Increasing machining productivity is the cause of constantly looking for new machining methods and methods to ensure the required quality. One of these methods is machining with rotary tool, which combines conventional cutting materials with an unconventional machining scheme. These properties allow to improve cutting conditions and thus increase productivity with preserved quality. In this paper, there is made the identification of properties and possibilities of using the rotating tool during turning. The main focus is the analysis and evaluation of technological parameters and surface quality, especially surface roughness.

Analysis of surface quality during fabrication of automotive retroreflectors

Due to their inherent functionality, retroreflective structures play a vital role in styling and safety that are typically associated with automotive lighting components. The optical performance of the automotive retroreflectors is strongly dependent on the quality of the functional facets that are involved in redirecting the incoming light. To date, virtually all automotive retroreflectors are fabricated through a conventional process commonly termed as “pin-bundling-electroforming” (PBE) or simply “pin-bundling” whose surface quality outcome is largely unknown despite the relatively venerable age of this manufacturing technology. To address this, the main goal of the present study was to perform a quantitative assessment of the quality characteristics associated with the three main phases of the PBE to be then contrasted with those of a newer and more versatile retroreflector fabrication technique called “ultraprecise single point inverted cutting” (USPIC). The results obtained showed that while the average areal roughness of PBE-generated inverted corner cube optical microstructures remains less than half than that of the USPIC-fabricated right triangular prism retroreflectors (9.2–9.5 nm vs 19.7 nm), their average waviness values remain comparable (29.9 nm vs. 32.9 nm). It is expected that the surface assessments presented in the scope of the present study will constitute a valuable baseline for future research efforts aiming to develop retroreflector-fabrication alternatives that are superior to PBE.

Investigation on machinability of the oxide layer in anodic oxidation of reaction-sintered silicon carbide by pure-water

Oxidation-assisted polishing has been developed as an efficient method for precision machining of reaction-sintered silicon carbide (RS-SiC), and characteristic of the oxide layer is the critical factor to obtain a fine surface property. Machinability of the oxide layer obtained in anodic oxidation of RS-SiC by the pure-water under high-frequency-square-wave potential is investigated by the ceria slurry polishing in this study. Quantitative analysis of surface quality of the oxidized RS-SiC sample is conducted by the scanning white light interferometer (SWLI) measurement. Along with increase of the oxidation time, surface quality of the oxidized RS-SiC is changing better at the beginning, and rapidly deteriorated in further oxidation process. Surface qualities of the RS-SiC sample before oxidation, after oxidation, after HF etching, and after abrasive polishing, are compared by the SWLI measurement. Surface roughness rms after anodic oxidation for 60min is 189.004nm. After removing the oxide by ceria slurry polishing, the rms can reach 3.688nm. Meanwhile, there is no visible scratch on the new revealed surface. Therefore, combination of anodic oxidation of RS-SiC by pure water and abrasive polishing of oxide layer by ceria slurry can be considered as an efficient method to machine RS-SiC.

Flow Behavior Characteristics and Processing Map of Fe-6.5wt. %Si Alloys during Hot Compression

The flow behavior of Fe-6.5wt. %Si alloys during hot compression was investigated at temperatures 650–950 °C and strain rates 0.01–10 s−1. The results showed that the flow stress depended distinctly on the deformation temperatures and strain rates. The flow stress and work hardening rate increased with the decrease of temperature and the increase of strain rate. The activation energy under all the deformation conditions was calculated to be 410 kJ/mol. The constitutive equation with hyperbolic sine function and Zener–Hollomon parameter was developed. The peak stress, critical stress, and steady-state stress could be represented as σ = A + Bln(Z/A). Dynamic recrystallization occurred under the deformation conditions where the values of Z were lower than 1020. Processing maps were established to optimize the processing parameters. The power dissipation efficiency decreased in the high temperature and low strain rate region, increased in the high temperature and high strain rate region, and remained unchanged in other regions with the increase of true strain. Furthermore, the unstable area expanded. The true strain of 0.7 was the optimum reduction according to the processing map. Based on the analysis of surface quality, microstructures, and ordered structures, the optimized processing parameters for the Fe-6.5wt. %Si alloys were the temperature and strain rate of higher than 900 °C and 0.01–10 s−1, respectively, or 800–900 °C and lower than 0.4 s−1, respectively.

Surface Quality Analysis of Cutting Tool Microgeometry to Achieve Higher Durability

Mapping surface quality changes during modification of the cutting tool microgeometry and reflecting on overall quality is the main purpose of this article. A complex view of microgeometry brings together the effects of indvidual stages in the processes which increase the cutting tool properties. The main objective is to increase the durability of the cutting tool. Grinding, microgeometry modification and deposition of a thin resistant layer on the cutting tool are the basic stages during the experiment. These stages have a significant effect on microgeometry parameters. Cutting edge radius, cutting edge symmetry (K factor), roughness of chipping and clearance surfaces are parameters affected by modification processes. Changing individual microgeometry parameters determines not only the surface quality of the cutting tool, but also affects the durability and stability of the cuting process. Appropriate microgeometry modification can make the cutting process more efficient. The combination of process stages and their influence on the quality of the microgeometry of the cutting tool is the primary objective in this article.

Technologie MuCell i InduMold w produkcji wysokiej jakosci detali samochodowych z tworzyw polimerowych

The article presents special injection molding techniques: MuCell® and InduMold used in the production of high quality automotive part on the example of the central console of Audi Q5 car. The mechanical, thermomechanical and thermal properties of the manufactured parts were examined and discussed with respect to changes in the structure of the material evaluated by scanning electron microscopy. The measurements were supplemented by surface quality analysis performed by optical microscopy. Research has demonstrated the ability to combine MuCell® and InduMold technologies in the production of high quality parts for the automotive industry.

Cutting surface quality analysis in micro ball end-milling of KDP crystal considering size effect and minimum undeformed chip thickness

Potassium dihydrogen phosphate (KH2PO4 or KDP) crystal is a typical soft-brittle optical crystal, and the size effect and brittle cutting mode are easy to appear in micro ball end-milling of KDP crystal. In this paper, micro-grooving experiments are conducted to study the size effect and brittle cutting in micro ball end-milling of KDP crystal with different feed rate and depth of cut. The cutting force, machined groove base quality and chip morphology are collected and analyzed carefully. The size effect is discovered by the phenomena of the existence of oscillations and relaxations in cutting force and hyper-proportional increase of specific cutting force, when the ratio of feed per tooth to cutting edge radius ft/re is less than 1. While the brittle cutting mode is detected through the existence of sharp fluctuations in cutting force and cracks on the groove base when the ratio ft/re is larger than 2. From the further comprehensive analysis of cutting force, specific cutting force, machined groove base quality and chip morphology, the cutting parameters with ratios of the maximum undeformed chip thickness in one cutting circle to cutting edge radius hmax/re around 0.14, 0.2 and 0.4 are regarded as size effect, optimal and brittle cutting points, respectively. The size effect, ductile cutting and brittle cutting zones are divided by the size effect and brittle cutting boundaries (points). Among the optimal points, the depth of cut of 2μm with the ratio ft/re of 1 is the optimal cutting parameter for micro ball end-milling of KDP crystal.