Surface Roughness Values Research Articles

CONTRIBUTION TO PRACTICAL ANALYSIS OF SURFACE ROUGHNESS MODELING DURING DRY HARD TURNING OF COLD WORK TOOL STEEL AISI D2

Quality of products is a major concern for hard machining industry aspects. However, the prediction of surface roughness in the function of the machining parameters is a targeted objective by the majority of researchers due to important industrial interest. This work is a contribution for developing comprehensive analyses of surface roughness models during dry hard turning of cold work steel AISI D2. It is focused on the treatment of predicted surface roughness values in correlation with cutting conditions such as cutting parameters (cutting speed, feed rate, and depth of cut), tools material, tool geometry, workpieces hardness, and machining times in order to establish of orientations for use which applied successfully in the industry from optimal selection of process variables. The approach consists in first conducting a literature survey through collecting and validating surface roughness models together with the corresponding material and also the cutting conditions. Then, results have been tabulated as to permit data mining treatment under data processing software which was developed. As a significant result, a strategic dashboard generating roughness data mining was made available to researchers and industrials. The optimums of parameters which condition the achievement of best machined surface qualities have been selected.

Pengaruh Kedalaman Pemakanan dan Kecepatan Potong pada Pembubutan Finishing Material Baja SKD 11 terhadap Kekasaran Permukaan Benda Bubutan

One important factor in achieving good quality value for a product in the machining process is to look at the level of roughness produced in the machining process. This research aims to determine the effect of feed depth and cutting speed on surface roughness. The process variables used in this research are feeding depth (mm) and cutting speed (m/min). Each variable has 3 levels, namely feeding depth of 0.5, 0.6 and 0.7 mm. Cutting speed 65, 70 and 75 m/min. In this research method, researchers used the full factorial method. The material used in this research is SKD 11 steel. The conclusion obtained from the research is that the minimum surface roughness is at a cutting depth of 0.6 mm with a cutting speed of 65 m/minute, with the average surface roughness value obtained being 0.883 (µm ). The maximum surface roughness is at a feed depth of 0.6 mm with a cutting speed of 70 m/minute with an average surface roughness value of 1.254 (µm).

The new Iridium-Hafnium-Aluminum alloy thin films with excellent mechanical properties and oxidation resistance

Improving oxidation resistance has long been a challenge for hot end components in high temperature environments. We have fabricated a series of IraHfbAlc (at. %) alloy thin films by multi-targeted direct current magnetron sputtering (DC-MS) and have thoroughly investigated the microscopic mechanism of the films. More importantly, we for the first time prepared IraHfbAlc alloy thin films with a preferred (111) orientation substitution solid solution, which exhibits excellent mechanical properties and oxidation resistance. The minimum surface roughness (Ra) value of the IraHfbAlc alloy films was 0.7 nm, while the maximum hardness (H) and elastic modulus (E) exceeded 20 GPa and 330 GPa, respectively. The oxidized volatility of the Ir in the films was only 0.11 μm/h at 1300 °C (lower than most previously reported values, such as 0.5 μm/h), which greatly improved the lifetime of the film. Confirmation that lattice distortion induces the refinement of crystal-like order (CLO) in thin films, and solves the mystery of enhanced oxidation resistance. The findings provide important insights into the design of Ir-containing alloy coatings and offer new ideas in the field of high-temperature protection.

Impact of air-polishing using erythritol on surface roughness and substance loss in dental hard tissue: An ex vivo study.

This ex vivo study aimed to investigate surface roughness and substance loss after treatment with different professional cleaning methods and to determine whether subsequent polishing with a rubber cup and polishing paste is necessary. Samples (flat and natural surfaces) of human enamel and dentin were prepared (baseline) and treated with either a curette, air-polishing with erythritol, a rubber cup and polishing paste, or a combination thereof (treatment). Subsequently, all samples were immersed in an ultrasonic bath (ultrasonic) to remove residues from the treatment procedures. The surface roughness values sRa and sRz as well as tissue loss were measured profilometrically. Linear regression models were used to compare group differences (roughness and loss) considering the corresponding baseline value. The significance level was set at p<0.05. sRa increased significantly after treatment with curettes or air-polishing with erythritol in both enamel (p<0.001) and dentin (p<0.001) of flat samples. The same effect was observed for sRz in dentin (p<0.001) but not for enamel compared to negative control. Polishing with a rubber cup and paste alone had no significant effect on roughness values. When combined with other treatments, the effect of curette or air-polishing with erythritol dominated the effect. In enamel, none of the tested methods led to measurable tissue loss. In dentin, air-polishing with erythritol caused ≤50% tissue loss compared to the curette. Conclusively, for enamel, treatment effects on roughness were measurable but of limited clinical relevance. For dentin, air-polishing resulted in a smaller but insignificant roughness increase and less tissue loss compared to the curette. Polishing with a rubber cup and paste did not affect surface roughness. Regarding the clinical application, the use of air-polishing seems to be a less invasive procedure than using a curette; polishing with rubber cup and paste offers no advantage in terms of reducing roughness as a final procedure.

Experimental and statistical investigation of electro-erosion machining performance of cryogenic treated hardened AISI H13 hot work tool steel

This study investigated the machinability of AISI H13 hot work tool steel with a hardness of 54 HRC, which has been deep cryogenically treated using the electro-erosion machining technique, one of the unconventional manufacturing methods. The machinability parameters used in the study were determined as current (4, 8 and 12 A), pulse time (200, 300 and 400 µs) and three different electrodes (Copper, Graphite and Tuncop). The experimental design was designed according to the Taguchi L27 model, and machinability tests were carried out to examine the results obtained from the experimental study both experimentally and statistically. When the literature was examined, it was seen that cryogenic treatment was generally applied to electrode materials, and only surface roughness and material wear amounts were examined as output parameters. The original value of the study is the interpretation of the results by applying cryogenic treatment to the test material and exploring the surface roughness and material wear amount, as well as the hole diameters and criterion diameters formed on the treated surfaces after the EDM process. As a result of the study, it was observed that the surface roughness value, the hole diameter, the amount of material wear, and the crater diameter increased with the increase in ampere and impact time. The lowest surface roughness value was 2.266 µm in the graphite electrode material at 4 amps and 200 µs impact time and the highest wear amount was realized as 0.555 g in the copper electrode material 12 amps and 400 µs impact time. The smallest hole diameter was 12.254 mm with a tuncop electrode with a pulse duration of 4 amps and 200 µs, and the lowest crater diameter was 127.301 µm with a graphite electrode at a current of 4 amps and a pulse duration of 200 µs. When the signal-to-noise ratios were examined, the optimum machining parameters for surface roughness, hole diameter, material wear amount, and crater diameter were determined as A2B1C1, A1B3C3, A3B1C1, and A3B1C1, respectively. When the ANOVA results are examined, it is determined that the most effective parameter for the surface roughness is of the current value with 86.54%, the most effective parameter for the hole diameter is the electrode material with 85.20%, the most effective parameter for material wear amount is the electrode material with 45.67% and the most effective parameter for the crater diameter is current value with 75.35%.

Surface Roughness Value Recommended for the Manufacture of Antibacterial Metal Surfaces: A Review

The manufacturing of antibacterial metal surfaces has been widely studied in the elaboration dental and orthopedic implants. Surface characteristics such as wettability, chemistry, electrostatics, and roughness have been described as factors for avoiding bacterial adhesion. However, surface roughness is still debated among authors regarding its effect on antibacterial surfaces. This paper reviews the existing literature to identify the recommended surface roughness values for metal implants to avoid bacterial adhesion, and it evaluates the different roughness parameters used in this regard. This compilation found no agreement when it comes to the exact roughness that a metal implant’s surface should have to avoid bacterial adhesion and the subsequent formation of biofilms. In general, different authors recommend manufacturing smooth surfaces with a nanoscale roughness, smaller than the size of the target bacterium.

Effect of Printing Layer Thickness on Optical Properties and Surface Roughness of 3D-Printed Resins: An In Vitro Study.

To investigate the impact of printing layer thickness on the optical properties and surface roughness of various 3D-printed resins manufactured by digital light processing (DLP) and indicated for provisional and definitive restorations. A total of 240 specimens from four different 3D-printing resins-VarseoSmile Crown Plus (Bego; VS), Crowntec (Saremco Dental; CR), GC Temp PRINT (GC Dental; TG), and NextDent C&B MFH (NextDent; ND)-were divided into four groups (n = 60 per group). Each group was further divided into three subgroups (n = 20) according to printing layer thickness (25, 50, and 100 μm). All specimens were subjected to thermocycling with coffee before measurements were taken with a spectroradiometer to calculate color differences. The Kubelka-Munk (K-M) absorption (K) and scattering coefficients (S), translucency parameters (TP), and surface roughness (Ra) values were calculated for each printing layer thickness and compared with those of the 2M2 shade tab (target). The data were analyzed using Mann-Whitney U test, the variance accounted for (VAF) coefficient by Cauchy-Schwarz, and post hoc comparisons using Tukey test (α ≤ .05). S (79% ≤ VAF ≤ 100%) and K (40.45% ≤ VAF ≤ 100%) spectral distribution depended on the wavelength. A 25-μm layer thickness resulted in no significant differences from the 2M2 shade for S (P > .230) and K (P > .200). VS showed significantly different S (P = .004) and K (P = .003) values from those of the shade tab with 50-μm layering thickness, whereas other materials did not show significant differences from the 2M2 shade for S (P > .280) and K (P > .301). The 100-μm layer thickness specimens had significantly different S and K values compared to the 2M2 shade tab (P < .004). TP values of resins with 100-μm layer thickness were significantly lower than resins in 25- and 50-μm layer thicknesses (P < .001). The Ra values of resins increased significantly with 100-μm layer thickness (P ≤ .001). All tested materials, except for VS, showed color properties similar to the target shade when 25- and 50-μm printing layer thicknesses were used. The translucency of resins tended toward an inverse relationship with printing layer thickness. The surface roughness of resins increased significantly with 100-μm layer thickness. However, all resins with a printing thickness of 25 μm showed better color properties and surface roughness.

Morphology and properties of PC/ABS notebook computer shell prepared by a combined in-mold decoration and microcellular injection molding process

In this paper, the PC/ABS notebook computer shells with PET film were prepared using a combined in-mold decoration and microcellular injection molding (IMD/MIM) process. Then the surface quality, morphology, impact toughness and wear resistance were investigated. The results shown that the surface quality is improved by IMD/MIM technology. The three dimensional surface roughness value (Sa) was about 1/3 of that of MIM parts. The cross-section of IMD/MIM samples have three layers. The first layer is a PET film decoration layer with about 132 µm thickness, followed by skin layer (about 22 µm) and foam layer. The range of thickness of the foam layer for the different specimens is about 7803 µm–7820 µm.The cell diameter is between 0.532 µm and 0.638 µm, which is about 2 times than that of MIM parts. Compared with MIM parts, the shape of the bubbles of IMD/MIM parts is ellipsoid with thinner wall. Moreover, the impact toughness of IMD/MIM parts are higher. The best impact toughness is 21.02 KJ/m2 within the scope of this experiment, which is 74% higher than the corresponding MIM part under the same foaming process. This may due to the PET film and micropores could block the initiation of the tip crack. Meanwhile, the IMD/MIM parts have excellent wear resistance property. In most cases, the wear rate of IMD/MIM parts is about 36.6% of MIM part under the same condition.

Evaluation of Stain Removal Efficacy and Color Stability of Three Different Dentifrices on Artificially Stained Enamel Surface-An In Vitro Study.

The aim of the present study was to assess the stain removal ability and color stability of three distinct dentifrices on artificially stained enamel surface. This study included 75 intact, healthy premolars free of dental caries that were extracted during orthodontic therapy. The samples were allowed to dry for 6 hours after being submerged in the prepared tea solution for roughly 18 hours every day. Then this procedure was repeated for seven successive days. All samples were randomly divided into three experimental groups with 25 samples in each group. Group I: control dentifrice, group II: dentifrice containing hydrogen peroxide, group III: dentifrice containing papain and bromelain. A specially designed toothbrushing simulator was used to brush every sample in the relevant group. Using a spectrophotometer and a measurement program, color measurement was evaluated after staining process after 4 weeks and 8 weeks of teeth cleaning. Using a profilometer, the surface roughness values (Ra) were assessed. After 8 weeks of brushing of stained samples, the color stability was better in dentifrice containing hydrogen peroxide (1.14 ± 0.11) followed by dentifrice containing papain and bromelain (1.22 ± 0.08) and control group (1.30 ± 0.09). And after 8 weeks of brushing of stained samples, the surface roughness was more in dentifrice containing hydrogen peroxide (0.237 ± 0.02) followed by dentifrice containing papain and bromelain (0.229 ± 0.13) and control group (0.207 ± 0.05). The present study concluded that the dentifrice containing hydrogen peroxide showed a superior whitening effect on the stained enamel surface than dentifrice containing papain and bromelain and control dentifrice. The development of various dentifrice products has been greatly aided by the increased demand for an improved esthetic appearance. Teeth's natural color and any external stains that could accumulate on the tooth surface combine to determine a tooth's color. Additionally, the use of whitening dental pastes to remove external stains has grown in favor. With the development of these whitening toothpastes, dentifrices' ability to lessen or eliminate extrinsic dental stains has increased. How to cite this article: Mishra D, Kamath DG, Alagla M, et al. Evaluation of Stain Removal Efficacy and Color Stability of Three Different Dentifrices on Artificially Stained Enamel Surface-An In Vitro Study. J Contemp Dent Pract 2024;25(1):68-71.

Correlating Frictional Forces Generated by Different Bracket Types during Sliding and Surface Topography Using Scanning Electron Microscopy and Optical Profilometer.

The study aims to correlate the frictional forces (FF) of four different types of commercially available ceramic brackets to their surface topography. Two monocrystalline (MC) brackets (CLEAR™, Adanta, Germany; Inspire ICE™, Ormco, USA), one polycrystalline (PC) bracket (Symetri Clear™, Ormco, USA), one clear hybrid esthetic bracket (DISCREET™, Adanta, Germany), and a stainless-steel (SS) bracket (Victory™, 3M Unitek, USA) served as control. Both static friction (SF) and kinetic friction (KF) were recorded during sliding using an Instron universal machine in dry settings. The bracket slot surface topography was evaluated. A scanning electron microscope (SEM) and a profilometer machine were used for assessment before and after sliding. Frictional forces values during sliding were as follows in descending order; Inspire ICE™, CLEAR™, DISCREET™, Symetri Clear™, and, lastly, Victory™. Also, DISCREET™ scored the highest in surface roughness (Sa) values followed by Symetri Clear™. None of the correlations were statistically significant. Frictional forces produced during sliding were not always directly related to surface roughness. Monocrystalline ceramic brackets appeared to have the greatest FF and a low surface roughness. Furthermore, DISCREET™ scored a very low frictional value comparable to metal brackets yet showed the highest surface roughness. Metal brackets exhibited the greatest surface smoothness before sliding and the least SF. Predicting the FFs produced during sliding mechanics would help the practitioner while choosing the bracket system to be used, and while planning the treatment mechanics, how much force to deliver, and how much tooth movement to expect. How to cite this article: AlBadr AH, Talic NF. Correlating Frictional Forces Generated by Different Bracket Types during Sliding and Surface Topography Using Scanning Electron Microscopy and Optical Profilometer. J Contemp Dent Pract 2024;25(1):41-51.

Improving the novel white coconut oil-based metalworking fluid using nano particles for minimum surface roughness and tool tip temperature

At present, nearly 85 % all of the requirement for MWFs are satisfied by the use of mixtures of petroleum by-products and synthetic substances with supplementary additives to enhance their properties. The demand for easily biodegradable, environmental friendly MWFs is a current requirement. COCOTP, a novel biodegradable MWF based on white (refined) coconut oil, developed by authors, had previously shown promising tribological properties for machining mild steel (MS) and stainless steel (SS) when used with the flooding method, but had fallen short of the performance of commercially available, non-biodegradable alternatives with MQL. Therefore in the current investigation, nano-particles were added to improve the performance of novel COCOTP MWF to use it with MQL conditions. Two nanomaterials nano-graphite and nano-Al2O3 were separately added to the base fluid in different concentrations as a monodispersed suspension. These nano enhanced fluids (NEFs) were subsequently used in straight turning experiments of two work materials AISI304 and SS400. Both the nano-enhanced fluids show convincing improvements over both COCOTP and mineral-oil based fluids in terms of surface roughness of the specimens regardless of the material being turned. However when machining SS 400, NEFs perform better only in lower speeds in terms of temperature. SS400 has a much higher thermal conductivity than AISI304 means that the quantity of residual heat remaining at the point of material removal which can be absorbed by the cutting fluid is lower in SS400. During machining SS400 under MQL lubrication 9.8 %, 26.8 % and 24 % reduction of surface roughness values (with respect to soluble oil) and during machining AISI304 55.3 %, 73.7 % and 70.4 % reduction of surface roughness values were obtained at 1175 rpm with COCOTP, NEF A and NEF G respectively. Based on the experimental results, the best-performing nano-enhanced fluids under MQL are 0.3 % (w/w) Al2O3 and 0.3 % (w/w) graphite.

Self-etching primer versus hydrofluoric acid and air-abrasion: effects on flexural and resin bond strengths of resin-based CAD/CAM material

This study aimed to evaluate the effect of self-etching primer (Monobond Etch & Prime; MEP), hydrofluoric acid (HF), and air-abrasion (A) protocols on shear bond strength (SBS) of resin cement and flexural strength (FS) of nanoparticle-filled resin-based CAD/CAM material. Bar- and rectangular-shaped specimens (n = 130 for each) were obtained from a resin-based material (Cerasmart 270). The specimens were divided into 13 subgroups according to surface treatments: Control (C); HF for 60, 90, and 120 s; MEP for 60, 90, and 120 s; air-abrasion for 10, 15, and 20 s; air-abrasion followed by HF; air-abrasion followed by MEP; HF followed by MEP. Surface roughness (Ra) values were measured using a profilometer (Surftest SJ-210) by applying 9 readings per specimen. One specimen per group was examined by atomic force microscopy (AFM; Multimode 8) in a 20 μm × 20 μm area, and scanning electron microscopy (SEM; EVO LS-10) under ×1000 magnification. FS and SBS data were obtained using a universal test device (Marestek) at a crosshead speed of 1 mm/min. Air-abraded groups showed the highest Ra (A10: 1.331 ± 0.213; A15: 1.409 ± 0.110; A20: 1.491 ± 0.111; A + HF: 1.415 ± 0.138; A + MEP: 1.309 ± 0.071 μm) and the lowest FS values (A10: 122.59 ± 16.80; A15: 118.94 ± 11.74; A20: 117.22 ± 11.18; A + HF: 114.42 ± 18.09; A + MEP: 128.98 ± 19.74 MPa). FS values of HF- and/or MEP-applied groups were statistically similar to the control group (C: 167.37 ± 27.02; HF60: 186.74 ± 30.66; HF90: 162.79 ± 29.31; HF120: 184.11 ± 17.18; MEP60: 171.98 ± 29.65; MEP90: 162.49 ± 20.38; MEP120: 173.55 ± 22.50; HF + MEP: 175.09 ± 21.64 MPa). SBS values of MEP-applied groups were higher than those of HF-etched groups with the same duration. Significant differences in SBS values were found after etching protocols with different durations (HF60: 4.14 ± 0.64; HF90: 4.48 ± 0.33; HF120: 6.76 ± 1.65; MEP60: 6.24 ± 1.23; MEP90: 9.92 ± 1.25; MEP120: 10.22 ± 1.27 MPa). Prolonged MEP application (90 s and 120 s) can be the preferred surface treatment for resin-based CAD/CAM materials. However, air-abrasion may adversely affect its mechanical properties.

Influence of Milling Feed Rate on Surface Roughness of Natural Fiber Composite

The influence of feed rate parameter of milling on natural fiber surface is investigated with constant 1700 rpm spindle speed. In this study, a surface texture-measuring instrument and optical microscope are used as measurement equipments. Ramie fiber composite samples are machined at 2, 4 and 6 mm/min feed rates each. The results shows that the sample machined at 4 mm/min feed rate has the lowest surface roughness value and its surface has a harmonious structure. In addition, many cracks and fractures appeared on the sample surface which machined at 6 mm/min feed rate due to the impact of the cutting edges.

Effect of surface roughness and polishing orientation on fatigue life and fracture fatigue entropy

AbstractThe effect of surface roughness and polishing orientation on fatigue life is investigated. Fully reversed bending fatigue tests are conducted on ASTM A1008 specimens having surface roughness asperities ranging from mirror finish (Ra = 0.05 μm) to coarse (Ra = 1.5 μm). Two polishing directions (i.e., orientations) are examined. For the range of roughness values tested, the results suggest that polishing orientation has a strong influence on fatigue life. Specifically, within the range of surface roughness values tested, fatigue life was found to be relatively insensitive to surface roughness asperities when the roughness orientation was parallel to the direction of surface stress but sensitive to surface roughness asperities when the orientation crossed the direction of surface stress. Results are generalized using the concept of fracture fatigue entropy (FFE). It is shown that, unlike fatigue life, FFE is independent of polishing orientation, a noteworthy result. To explain the behavior of FFE in relation to surface roughness asperities, a fatigue thermodynamics theory is presented that hypothesizes that all specimens of the same material fail at equivalent entropy levels.

Effect of Sterilization and Irrigating Solutions on Nanostructure Alteration of Ni-Ti Rotary Instruments in Endodontics: An Atomic Force Microscopic Study.

This study aimed to evaluate the effect of 5.25% sodium hypochlorite (NaOCl) and 17% ethylenediaminetetraacetic acid (EDTA) and sterilization on the nanostructural alteration of nickel titanium (Ni-Ti) rotary file systems in endodontics using the atomic force microscopy (AFM). The study was performed on four commercially available rotary Ni-Ti files: group I-Vortex Blue (Dentsply), group II-ProTaper Next (Dentsply), group III-Mtwo (VDW), and group IV-iRaCe (FKG). Each group was divided into four subgroups (n = 4), that is, subgroup A-control (new rotary file), subgroup B-subjected for five cycles of autoclave, subgroup C-immersed in 5.25% NaOCl for 5 minutes, and subgroup D-immersed in 17% EDTA solutions for 5 minutes. All the specimens were evaluated with AFM using roughness average (RA) and root-mean-square (RMS) values for surface roughness. Among control groups, Vortex Blue showed the least RA and RMS values; the highest surface roughness was seen with Mtwo files. All the Ni-Ti rotary files showed a statistically significant (P <0.05) increase in surface hardness when subjected to autoclave and treatment with different irrigating solutions. In particular, 17% EDTA caused the highest surface deterioration in all the groups. AFM analysis revealed increased surface roughness values recorded for all the rotary files when treated with irrigating solutions and autoclave cycles.

Investigation of the Surface Roughness and Hardness of Different Denture Teeth Materials: An In vitro Study

ABSTRACT Background: Surface roughness and hardness are key factors that influence the clinical performance and durability of denture teeth. Understanding variations in these properties among different denture teeth materials can assist in selecting the most suitable materials for optimal patient outcomes. This study aimed to investigate the surface roughness and hardness of four commonly used denture teeth materials: acrylic resin, composite resin, porcelain, and nanohybrid composite. Materials and Methods: Ten specimens were prepared for each denture teeth material, resulting in a total of 40 specimens. Surface roughness was assessed using a profilometer, and measurements were recorded in micrometers (μm). Hardness was determined using a Vickers hardness tester, and results were expressed as Vickers hardness numbers (VHN). The surface roughness and hardness data were analyzed using appropriate statistical tests (e.g., analysis of variance), with significance set at P &lt; 0.05. Results: The results revealed significant differences in both surface roughness and hardness among the different denture teeth materials (P &lt; 0.05). Acrylic resin exhibited the highest surface roughness (mean ± standard deviation: 3.45 ± 0.78 μm) and the lowest hardness (mean ± standard deviation: 45.6 ± 2.3 VHN). Composite resin demonstrated intermediate values of surface roughness (mean ± standard deviation: 1.87 ± 0.54 μm) and hardness (mean ± standard deviation: 65.2 ± 3.9 VHN). Porcelain demonstrated the smoothest surface (mean ± standard deviation: 0.94 ± 0.28 μm) and the highest hardness (mean ± standard deviation: 78.5 ± 4.1 VHN). Nanohybrid composite displayed surface roughness and hardness values similar to composite resin. Conclusion: This study demonstrated significant variations in surface roughness and hardness among the different denture teeth materials evaluated. Acrylic resin exhibited the roughest surface and lowest hardness, while porcelain demonstrated the smoothest surface and highest hardness. Composite resin and nanohybrid composite exhibited intermediate values. These findings provide valuable insights for prosthodontic practitioners in selecting denture teeth materials based on specific clinical requirements, aiming to achieve optimal aesthetics, reduced plaque accumulation, and improved wear resistance.

Comparison of volumetric loss and surface roughness of composite dental restorations obtained by additive and subtractive manufacturing methods

Statement of problemPermanent crown materials produced with new generation additive manufacturing and traditional subtractive manufacturing materials have not been compared in terms of wear resistance. PurposeThis study aims to compare the volumetric loss related to wear and resulting surface roughness after aging in a chewing simulator between resin nano ceramics produced with milling technique and permanent crown materials produced with three dimensional (3D) printing. Materials and methodsThree different hybrid composite-ceramic (HCC) (The three materials are GC: Cerasmart, VE: Vita Enamic, and GV: Grandio Voco.) and one 3D printed definitive crown resin (FormLabs Permanent Crown Resin) were investigated before aging (n:8), the surface roughness of all samples was measured with a profilometer, and 1 randomly selected sample from each subgroup was imaged with scanning electron microscope (SEM). 3D scans of each sample were obtained with a desktop scanner. Thermomechanical aging was performed using a chewing simulator. Four hundred thousand cycles were completed under a vertical occlusal force of 49 ± 0.7 N with a thermal cycle of 1.7 Hz 5–55° and with a dwell time of 120 s, mimicking 2 years of aging. The imaging procedures were repeated, and the change in surface roughness was evaluated. 3D images were also overlapped, and the volumetric loss was calculated with the relevant inspector software. The data obtained were analyzed by two-way ANOVA (p < 0.05). ResultThe results showed significant statistical differences for both parameters (p > 0.05). The highest volumetric loss was found in the GV group while the lowest volumetric loss was in the VE group. The highest surface roughness values were observed in the GV group, while the lowest values belonged to the VE one. ConclusionOf the restorative materials evaluated, the VE group is suitable for long-term restorations, whereas the GV one is suitable for medium-term restorations. It is promising in terms of 3D printing technologies that the 3D material gives comparable results with the GV group. Clinical i̇mplicationAdditive manufacturing techniques are a successful method that accelerates the manufacturing process. Permanent crown resins are promising alternatives to conventional production.

Investigation of machining rate and surface roughness in wire EDM of Al6063/WC/ZrO2 composite using response surface methodology

The aim of the current work is to explore the machinability behavior of Al6063/WC/ZrO2 metal matrix composites (MMC) produced through a stir casting process through wire electrical discharge machining (WEDM) process. In order to examine the effects of process parameters such as voltage (V), pulse on time (Ton) and pulse off time (Toff) on material removal rate (MRR) and surface roughness (SR), the experiments were conducted by adapting Response Surface Methodology (RSM) in conjunction with the central composite design (CCD). A second-order regression model has been developed to predict the response parameters and an analysis of variance (ANOVA) was performed to validate the significance of the models. Using the desirability function approach, the parameters were set for the highest MRR and the minimum SR value. The prediction was within a tolerable average error range. A total of 19 sets of tests were developed to obtain six possible solutions. The most suitable solution among these six has been found by a confirmatory experiment. The results indicate that voltage and its interactions have significantly affected both the responses than Ton and Toff. Overall, it can be said that the study of the Al6063/WC/ZrO2 MMCs using WEDM process parameters demonstrated improved casting and machining qualities.

Investigation on the Application of Worn Cutting Tool Inserts as Burnishing Tools

The amount of wear in cutting tools used in all machining processes is around 1 % to 2 % evaluation of the non-wearing areas of the inserts is economically beneficial. This study aims to test the usability of the non-wearing regions of the waste tungsten carbide (WC), cubic boron nitride (CBN) and ceramic inserts as a rolling tool in the deep rolling method and to observe their performance. The turned workpieces were deep rolled with three different types of waste-cutting tools (WC, CBN and ceramic) in different machining parameters (rolling force, number of passes, and feed rate). As a result, surface roughness and microhardness values obtained in deep rolling operations with these inserts were similar to those in deep rolling operations with other rolling tools. It has been determined that ceramic inserts perform better in deep rolling processes in terms of microhardness, and WC inserts perform better in terms of surface roughness. Thus, it has been determined that waste WC, CBN and ceramic inserts can be used in the deep rolling method.

Experimental study on electrical discharge machining of porous and pure 316L stainless steel

Porous metal materials are widely used in heat-absorbing, biomedical parts and other fields because of their excellent mechanical properties and biocompatibility. Further applications of porous metal materials are inseparable from secondary precision machining. However, traditional cutting methods tend to compromise the original porosity of the material surface. Electrical discharge machining (EDM) is a type of non-conventional machining method which is more preferable to overcome these defects. In the present study, the main target is to investigate the effect of four input electrical machining parameters (current, frequency, efficiency and gap voltage) on the five output responses (material removal rate (MRR), electrode wear, surface roughness (SR), noise and time consumption value of environmental particulate matter (PM2.5)) when electrical discharge machining porous 316L stainless steel and compared with that of pure 316L stainless steel. The Taguchi method was employed to determine the relationship between electrical discharge machining parameters and output responses. The analysis of variance (ANOVA) was used to evaluate the effect of input parameters on output responses. The effects of electrical machining parameters on above responses were analyzed by main effects, and the order of influence was obtained, respectively. Finally, the surface morphology was observed by scanning electron microscope (SEM), and the effect of electrical machining parameters on the characteristics and formation of machined surface of porous stainless steel was mainly analyzed.