Levels Of Surface Roughness Research Articles

MoS2 Coatings in unsynchronized, dry-running Screw Compressors: Experimental Insights on Operational Efficiency and Durability

Abstract The discourse on unsynchronized, oil-free screw compressors versus their conventional, oil-lubricated counterparts encapsulates a pivotal shift towards more effi-cient and environmentally friendly industrial machinery. By forgoing gears and lubricants, these innovative compressors streamline manufacturing and assembly, while also eliminating the risk of lubricant contamination in the process gas. In this configuration, the torque generated on the gate rotor by the gas pressure is directly conveyed to the main rotor through the interfacing surfaces of the rotors. In the development of compressor technology, a significant improvement is the application of a molybdenum disulfide (MoS2) coating on the primary rotor. This application utilizes the properties of molybdenum disulfide, which is effective in reducing friction and wear under various operational conditions. By applying this coating, there is an anticipated increase in the wear resistance of the rotor, effectively reducing frictional losses during its operation. This reduction in friction is expected to improve the mechanical efficiency of the compressor and extend its operational lifespan. The investigation of contact interactions utilizes a custom-designed test rig, through which effective parameters are analyzed to facilitate conclusions regarding losses and the durability of the coating. Additionally, the geometry within the contact area is tactilely measured, enabling the quantitative determination of wear. Various layer thicknesses, surface roughness levels, and loads are examined in this context.

Surface Plasmon Polariton Photoluminescence Enhancement of Single InP Nanowires with InAsP Quantum Wells

A significant (up to 4 times) photoluminescence enhancement of single InP/InAsP/InP nanowires transferred onto a silicon oxide‐covered silver layer on silicon substrate with a metal surface roughness level of less than 1 nm and a dielectric thickness of 5 nm has been demonstrated. This phenomenon is explained by the interaction of electron–hole pairs in the semiconductor with surface plasmon polaritons. The photoluminescence kinetics and results of modeling confirm the indicated enhancement mechanism.

Thermal-mechanical Coupling Model of Angular Contact Ball Bearing and the Influence of its Surface Roughness

Abstract A model that integrates thermal and mechanical aspects for an angular contact ball bearing (ACBB) has been introduced, considering its surface roughness. Subsequently, the analysis of friction torque, clearance, contact force, and temperature within the bearing is conducted under varying levels of surface roughness based on the established model. Additionally, the characteristics of thermal-mechanical coupling are examined under different conditions. The results indicate a significant interdependence between temperature and contact forces in the bearing system. It is observed that both friction torque and temperature increase with increasing surface roughness. This analysis provides valuable insights into the thermal-mechanical coupling characteristics of bearings.

Predictive Model for Scuffing Temperature Field Rise of Spiral Bevel Gears under Different Machining Conditions

Spiral bevel gears are extensively employed in mechanical transmissions; however, they are prone to adhesive wear when operating under high-speed and heavy-load conditions. Research indicates that the tooth surface roughness of gears significantly influences the friction and wear of the meshing gears. The present study delves into the origins of tooth surface roughness through the integration of the W-M function and fractal theory. Utilizing an involute helical gear with surface roughness for tooth cutting, a three-dimensional model is established with roughened tooth surfaces. This paper introduces an approach to developing three-dimensional gear models with roughness and applies the finite element method to perform thermodynamic analysis on gears exhibiting diverse levels of surface roughness. The thermal analysis of gears with varying degrees of roughness was conducted using the finite element method. Comparative analysis of the results under specific operating conditions elucidated the impact of roughness on tooth surface temperature rise. In order to validate the simulation model, an experimental test platform for spiral bevel gears of identical size was established. This model integrates tooth surface roughness with thermodynamic analysis, allowing for the rapid assessment of tooth surface temperature rise under different machining conditions, and reducing the cost of validating predicted tooth surface load-carrying capacity.

Impacts of Material and Machine on the Variation of Additively Manufactured Cooling Channels

Abstract While additive manufacturing (AM) can reduce component development time and create unique internal cooling designs, the AM process also introduces several sources of variability, such as the selection of machine, material, and print parameters. Because of these sources, wide variations in a part's geometrical accuracy and surface roughness levels can occur, especially for small internal cooling features that are difficult to post-process. This study investigates how the selection of machine and material in the AM process influences variations in surface quality and deviations from the design intent. Two microscale cooling geometries were tested: wavy channels and diamond-shaped pin fins. Test coupons were fabricated with five different additive machines and four materials using process parameters recommended by the manufacturers. The as-built geometry was measured non-destructively with computed tomography scans. To evaluate surface roughness, the coupons were cut open and examined using a laser microscope. Three distinct roughness profiles on the coupon surfaces were captured including upskin, downskin, and channel walls built at 90 deg to the build plate. Results indicated that both material and machine contribute to producing different roughness levels and very different surface morphologies. The roughness levels on the downskin surfaces are significantly greater than on the upskin or sidewall surfaces. Geometric analysis revealed that while the hydraulic diameter of all coupons was well captured, the pin cross section varied considerably. Along with characterizing the coupon surfaces, cooling performance was investigated by experimentally measuring friction factor and heat transfer. The variations in surface morphology as a function of material and machine resulted in heat transfer fluctuating by up to 50% between coupons featuring wavy channels and 26% for coupons with pin fin arrays. Increased arithmetic mean surface roughness led to increased heat transfer and pressure drop; however, a secondary driver in the performance of the wavy channels was found to be the roughness morphology, which could be described using the surface skewness and kurtosis.

Comparison of polishing methods for two types of monolithic all-ceramic crowns after occlusal adjustments: Polishing paste versus glazed porcelain.

This study compared the effects of two surface preparation methods on two types of zirconia. Immediately prior to the placement of a monolithic zirconia crown, its morphology may be modified using a rotary cutting instrument for occlusal adjustments. The crown surface is scratched during the grinding process and, thus, requires polishing. Simplified zirconia crowns of 3Y and 5Y were fabricated and used as specimens. The surface roughness and gloss of the occlusal surfaces of specimens were measured and compared when a polishing compound was used after polishing points and when a silica-based coating was sintered. No significant differences were observed in surface roughness between 3Y and 5Y zirconia. The use of polishing compounds was effective because polishing points alone only resulted in a level of surface roughness that may cause wear on antagonist teeth. Although the silica-based coating improved surface properties, the polishing compound more effectively improved surface roughness.

Fatigue damage mechanics approach to predict the end of incubation and breakthrough of leading edge protection coatings for wind turbine blades

The state of the surface of the leading edge of wind turbine blades is important for optimal aerodynamic performance. Rain erosion leads to damage and roughness on the leading edge. In this study, we present an approach to predict the level of roughness of the leading edge based on fatigue damage accumulation due to impacts of rain droplets. Impact simulations of droplets on the protective coating layer are coupled with rain erosion test data and fatigue S-N curves. Fatigue damage values are then related to surface roughness levels. An approach to extract S-N curve parameters from a rain erosion test and then make predictions for other coatings based only on the output of impact simulations is presented and tested against test data. Both the end of incubation and coating breakthrough times are predicted with this approach. Stress, strain and energy density values were used as fatigue damage indicators and the respective predictions were compared to each other. It was found that the maximum principal strain gave the best predictions and matched the experimental trends.

Experimental Investigation of Machinability of Filler Weld Applied to DIN 1.2379 Tool Steel by Milling Method

Multi-purpose designed and manufactured constructions may also wear out over time, and breakage or rupture may occur as a result of this wear. In terms of cost, it is more economical to produce these parts by the welded joining method instead of reproducing them. In this context, in this study, a filler welding process was performed on DIN 1.2379 cold work tool steel materials with a welded joining process. The surfaces formed as a result of the filling process were machined by the milling method on a CNC milling machine. The investigation revealed that when cutting speed increased, surface roughness levels reduced. The opposite was observed for the cutting forces with increasing cutting speed. It was found that feed rate had the greatest impact on both cutting force and surface roughness. Regression analysis was used to create prediction equations for surface roughness and cutting force, and the outcomes of the experiments and predictions were compared.

In Vitro Effects of Sof-Lex, Eve, and Astropol Polishing Systems on Composite Resin Surface Roughness after Aging.

Objectives: Surface roughness is one of the important properties of composite restorations. Different polishing systems are used to provide an appropriate composite restoration surface. The aim of this study was to evaluate the effects of Sof-Lex, Eve, and Astropol polishing systems on composite resin surface roughness after aging. Materials and Methods: In this in vitro study, 36 composite discs (8×2mm) were fabricated. The specimens were randomly divided into three groups (N=12) for polishing with (I) Sof-Lex (3M ESPE), (II) Eve (Ernst Vetter GmbH), and (III) Astropol (Ivoclar/Vivadent) polishing systems. The specimens were then subjected to thermocycling. Surface roughness of the specimens was measured before and after polishing, and after thermocycling by a contact profilometer. Repeated Measures ANOVA was used to analyze the data (α=0.05). Results: Although Astropol showed slightly higher surface roughness in comparison to Sof-Lex and Eve, the level of surface roughness before and after polishing and after aging was not significantly different among the three polishing systems (P=0.704). Conclusion: Within the limitations of this in vitro study, Sof-Lex, Eve, and Astropol showed similar acceptable results with regard to composite resin surface roughness.

Biomechanical surface roughness analysis of ramie-low melt polyester nonwovens exposed to plasma

This study aims to characterize ramie-low melt polyester nonwoven fabrics treated with low-temperature plasma and to analyze 3-D images based on object-depth mapping (ODM) using the MATLAB® R2022a software. We examined the low-temperature plasma treatment of nonwoven ramie fabrics using a plasma generator with 30 kV output power, six-minute treatment times, and a 4.5 cm distance between electrodes. The fabric’s chemical properties and surface topography were investigated using scanning electron microscopy (SEM) and infrared spectroscopy (FTIR). An analysis of the SEM images was performed using a statistical approach and image processing to determine the level of surface roughness. FTIR analysis revealed that fabrics exposed for six minutes differed from those that were not. Our findings indicated that plasma treatment caused the following: 1) Ramie fabrics to become more hydrophilic, as shown by their increased T% in the FTIR of hydrophilic functional groups such as hydroxyl (O-H), carboxyl (-COOH), and carbonyl (C=O); 2) A higher surface roughness was observed in nonwoven fabric during SEM testing and image processing; 3) Plasma treatment of fabrics resulted in a higher coefficient of variation (CV) than untreated fabrics; 4) Nonwoven fabric mass reduction. Based on this study, we found the relationship between plasma-treated ramie fabric and textiles in biomechanics. Plasma treatment reduced the mass of ramie fabric by 0.11 %, according to our findings. We found that the greater the mass reduction, the greater the surface roughness value. The novelty of this study is the use of 3-D images based on object-depth mapping (ODM) using the MATLAB® R2022a software in SEM to observe surface roughness to the physical properties of ramie fabric for the first time.

Effects of current intensities on material removal rate, electrode wear rate, and surface roughness of machining high carbon high chromium steel

AbstractThe electrical discharge machining is very successful and generally recognized for producing complicated shapes and small openings with exceptional precision. The objective of this study is to assess the impact of different electrical discharge machining parameters on the attributes of the machining process. The evaluation of the machining process was conducted based on the workpiece‘s material removal rate, the rate at which the electrodes wear, and the level of surface roughness. Simultaneously achieving a high material removal rate, low electrode wear rate, and high surface roughness is not possible with a specific combination of approaches due to their contradicting nature. Frequently, it is necessary to independently apply many measures instantaneously in order to assess their impact on various responses. This research investigates the machining of high carbon high chromium steel making use of electrical discharge machining with aluminum, copper, and graphite electrodes. The study focuses on the impact of different current intensities on the rate of material removal, electrode wear, and surface roughness. The experimental results demonstrate that the highest material removal rate (mmcubicmin−1) is achieved at a current density of 12 A when using a copper electrode (54.67), as opposed to aluminum electrode (22.91) and graphite electrode (29.43).

Investigating the Role of Flow Plate Surface Roughness in Polymer Electrolyte Membrane Fuel Cells with the Use of Multiphysics Simulations

This study investigates the influence of surface roughness on the performance of polymer electrolyte membrane fuel cells (PEMFCs) through computational simulations using COMSOL Multiphysics. Two distinct gas flow channel (GFC) models of serpentine and parallel GFC structures were analysed, featuring various surface roughness levels to examine their impact on gas pressure and velocity dynamics. Rough surfaces are modeled using trigonometric functions to replicate machining-induced variations. Finite element simulations were conducted, assessing the time-dependent relationship between gas pressure and velocity while considering different electrode phase potentials as a function of surface roughness. Rough surfaces generally enhance mass transport, water management, and current distribution compared to smooth surfaces. The results indicated that a surface roughness of approximately 1 µm optimizes PEMFC performance by balancing pressure and velocity, enhancing electrochemical reactions, and reducing excessive pressure drops within the cell. Notably, the 0.7 V operating voltage was found to be the most efficient, achieving rapid stabilization of pressure and velocity levels swiftly. The findings underscore the importance of precise control over GFC roughness to enhance PEMFC performance gains in commercial applications, especially when multiple cells are stacked to achieve high power outputs.

Melt Pool characteristics on surface roughness and printability of 316L stainless steel in laser powder bed fusion

Purpose Surface quality and porosity significantly influence the structural and functional properties of the final product. This study aims to establish and explain the underlying relationships among processing parameters, top surface roughness and porosity level in additively manufactured 316L stainless steel. Design/methodology/approach A systematic variation of printing process parameters was conducted to print cubic samples based on laser power, speed and their combinations of energy density. Melt pool morphologies and dimensions, surface roughness quantified by arithmetic mean height (Sa) and porosity levels were characterized via optical confocal microscopy. Findings The study reveals that the laser power required to achieve optimal top surface quality increases with the volumetric energy density (VED) levels. A smooth top surface (Sa < 15 µm) or a rough surface with humps at high VEDs (VED > 133.3 J/mm3) can serve as indicators for fully dense bulk samples, while rough top surfaces resulting from melt pool discontinuity correlate with high porosity levels. Under insufficient VED, melt pool discontinuity dominates the top surface. At high VEDs, surface quality improves with increased power as mitigation of melt pool discontinuity, followed by the deterioration with hump formation. Originality/value This study reveals and summarizes the formation mechanism of dominant features on top surface features and offers a potential method to predict the porosity by observing the top surface features with consideration of processing conditions.

Comparative analysis of surface roughness level for bearing coating using VMD of vibration signal

Degradation in surface finish of the material is an important concern in engineering applications. However, most of the conventional techniques available to monitor the surface roughness requires dismantling of the machine element. Though in rotary components like bearing, it is practically not feasible. Therefore, in this work, an on-board technique is proposed to compare the level of surface roughness based on vibration signature. To demonstrate, five different industrial standard coatings (Nickel, Copper, Zinc phosphate (ZnP), Silver, and Black oxide) were carried out on raw five ball bearings (NBC6205). Two sets of coated bearing were prepared, where first set was utilised for experimentation and second for the purpose of measuring surface roughness of bearing surface. These coated bearings were tested at five different RPMs ranging from 300 RPM to 1500 RPM and their vibration signals were recorded. The recorded vibration signals must be having characteristics originated from ball rolling on different level of surface roughness and hence distributed in nature. Further, to target distributed characteristics present in the signal, commonly used statistical parameters for vibration signature analysis (RMS, Crest factor, Variance, Skewness, Kurtosis, Shannon entropy and Log energy) were calculated. Then, correlation of the parameters was checked in relation to the different levels of surface roughness but no relation was found. The signals were then decomposed into six intrinsic mode functions (IMFs) using Variational Mode Decomposition (VMD) method. Again, same statistical parameters were calculated for these decomposed levels, it has been noted that Shannon entropy have shown correlation to surface roughness in at least one decomposed level between 900 to 1500 RPM with minimum value of chain index as 176.65. Moreover, in this RPM range, responsive frequency bands found to be shifted towards higher side i.e. from 567 to 4590 Hz.

In Vitro Evaluation of Color and Surface Roughness Changes of Polyetheretherketone, Monolithic Zirconia, and Resin Nanoceramics Exposed to Staining Liquids.

This study aims to investigate color stability and surface roughness of polyetheretherketone (PEEK), zirconia, and hybrid ceramics while stored in different liquids. A total of 240 specimens were prepared from monolithic zirconia, PEEK, and hybrid ceramics. All specimens were polished using rubber sets with different grain sizes. Color parameters (L*, a*, b*) were measured three times using a dental spectrophotometer in standard D65 lightning. Each group was divided into eight different groups to be kept in eight different solutions as distilled water, cola, red wine, tea, coffee, heptane, citric acid, and 50% ethanol. Specimens were held in solutions at 37°C for 12 days. Color measurements were repeated, and color change (ΔE) was calculated using the CIE Lab formula. The color difference of PEEK specimens was found above the clinically acceptable limit; however, color differences for monolithic zirconia produced by coffee were found within the clinically acceptable limits. ZR and HC specimens' color change values were found between threshold values (1<ΔE < 3.3). The differences observed in surface roughness levels amongst the ZR specimens could be caused by the polishing instrument and procedure. The color change of the materials was within acceptable limits, whereas the surface roughness increased more than 0.2 µm. Especially cola, heptane, and red wine significantly increased the mean surface roughness.

RANS study of surface roughness effects on ship resistance

Abstract In marine engineering, optimizing the performance of vessels is a key issue, particularly in increasing fuel efficiency, reducing operating costs, and minimizing environmental impact. One of the most critical determinants of vessel efficiency is hull resistance, which directly affects fuel consumption, power requirements, and cruising speed. We aim to investigate how surface roughness affects hull flow resistance, to quantify the drag variation at different surface roughness levels using special wall functions that reproduce boundary layer dynamics. This approach involves the complex interaction between the intricate complexity of roughness and the nonlinear pressure drag effects on the hull. The KVLCC2 ship model is used as a representative prototype in the CFD analysis based on the RANS equations and the k-omega SST model to independently evaluate the roughness effects on individual ship sections. The comparative analysis with empirical data reveals the complex relationship between surface roughness and ship resistance and provides insights for ship design and operational improvement. The study investigates the interaction between drag coefficient and vessel performance to improve hydrodynamic efficiency.

An Experimental Study of the Frictional Behavior at the Interface Soil-Structure with Regards to Wall Friction Effect and Clogging Related to Surface Roughness Form

Abstract The interactions between soil-structure are largely governed by the shear strength at the soil-structure interface, particularly in situations involving large displacements, known as shear residual strength. This latter can be influenced by a range of factors, including normal stress, physical properties, surface roughness, wall friction. The main objective of this study is to investigate clogging related to surface roughness form, in addition to wall friction arises from consolidation. In order to investigate the impact of wall friction, experiments involving ring shear tests were carried out on kaolin. Four different consolidation durations were employed to induce varying settlements of the upper platen, while three distinct testing procedures, including single stage, multistage, and preshearing, were utilized. Additionally, different levels of surface roughness were incorporated to investigate the effect of clogging. The test results obtained from various testing procedures indicate that employing a single stage procedure with zero consolidation time is the most suitable approach for mitigating the influence of wall friction. For clogging effect, is dependent on the materials used, namely, the kaolin and the mixture, as well as, the interfaces involved.

Polycaprolactone (PCL)-based films integrated with hairy cellulose nanocrystals and silver nanoparticles for active Tilapia packaging applications

The migration of metal ions to the food matrix has been always a challenge in the production of active food packaging films. In this study, it was tried to evaluate the idea of using hairy cellulose nanocrystals (HCNs) in controlling the migration of Silver Nanoparticles (AgNPs) from polycaprolactone (PCL)-based films to the Tilapia fish. HCNs and the final films (integrated with various amounts of HCNs and AgNPs) were evaluated physicochemically and mechanically. Tilapia fish were packed using the films and after specific periods, the fish samples were assessed microbiologically and physiochemically. According to the results, incorporating NPs into PCL films enhanced tensile strength, elasticity, and toughness making the films more resistant to breakage and deformation under stress. The introduction of HCNs reduced the surface roughness level, decreasing AgNPs migration, but also accelerated the degradation rate. Films with [1% AgNPs +2% HCNs] and [1% AgNPs] had the lowest and highest water vapor transmission rate. The use of AgNPs (1%) + HCNs (2%) incorporated into PCL films resulted in a lower pH value, TVB-N, TBARs, and PV. It also decreased microbial activities in samples in comparison to the control. Therefore, the idea of using HCNs along with antibacterial metal-based nanoparticles can control the rate of ion migration.

Effect of Cutting Speed on Surface Roughness AS-Scrapper ST37 Using Coated Carbide Tool

In the lathe machining process, especially surface roughness, are greatly influenced by the cutting angle of the tool, feeding speed, cutting speed and depth of cut. Research purposes is to determine the effect of cutting conditions, namely cutting speed (v) and cutting depth (a) on the level of surface roughness (Ra) on the ST37 As Scrapper material using quantitative research methods that focus on numeric or numbers in a study. The research results obtained a value of Ra ⃗= 6.063 µm at optimum cutting conditions varying a= 1 mm, v= 62 m/min, f= 0.05 mm, tc= 5.29 min.

Effect of process parameters on the mechanical behavior of Ti6Al4V alloys fabricated by laser powder bed fusion method

The parameters used in the production process in laser powder bed fusion (L-PBF) technology, one of the additive manufacturing methods, have a critical effect on the mechanical behavior and density properties of the product and can change the properties of the product. Therefore, this study examined the influence of laser power, scanning speed, hatch spacing and beam rotation angle on the tensile strength, impact energy, surface roughness, and porosity levels of Ti–6Al–4V produced through the L-PBF method. It was observed that the tensile strength changes directly proportional to the laser power. In addition, the tensile strength decreases significantly with a value of 645 MPa obtained at lowest 0.07 mm hatch spacing, 190 W laser power and 900 mm scanning speed. The lowest value of impact energy, with a value of 8.7 J, was reached at a rotation angle of 180°. It has been determined that surface roughness decreases significantly with increasing laser power, while it demonstrates an increase with higher scanning speeds. Surface roughness values of 8.9 μm parallel and 8.35 μm perpendicular to the building direction were achieved at a laser power level of 220 W. Laser power was identified as the most influential factor in determining the porosity ratio, with a high porosity rate 0.48% occurring at 160 W laser power. Furthermore, an increase in scanning speed resulted in a corresponding increase in the porosity rate.