Surface Roughness Values Research Articles

Experimental investigation on in-situ laser-assisted machining of single crystal silicon based on response surface methodology

Abstract In this paper, Response Surface Methodology (RSM) was utilized as a robust and convenient predictive tool to establish the correlation between process parameters in in situ laser-assisted machining and the surface roughness of single-crystal silicon. An optimized design of the diamond tool, a novel temperature field analysis method, and Response Surface Methodology (RSM) were utilized. The contribution rate of each process parameter on surface roughness was laser power > rotation speed > cutting depth > feed rate. The optimal process parameter combination is: rotation speed as 1001 r min−1, feed rate as 4.9 μm/r, cutting depth as 7.55 μm, and laser power as 28.81 W. Experimental validation of these optimal parameters compared surface roughness values obtained experimentally with those predicted. The surface roughness model showed a maximum relative error of 5.2%, with an average error of 4.8% across three experimental sets. These errors are within acceptable limits, indicating an alignment between predicted and experimental results.

THE INFLUENCE OF THE CUTTING PARAMETERS ON THE SURFACE ROUGHNESS AND VIBRATION SIGNAL IN THE TURNING PROCESS

The performance of the final part of the turning process, a topic of practical importance, heavily depends on the cutting parameters. Surface quality, a crucial product attribute in manufacturing, often tops consumer demands during machining due to its significant influence on product functionality. This paper assesses the correlation between the detected vibration signal, statistical parameters (Crest, Kurtosis and I-kaz3D coefficient) and surface roughness and provides valuable insights for practical applications. When the tool experiences vibrations during material removal, these oscillations leave a ripple effect on the surface of the workpiece. We aim to determine the impact of cutting parameters on surface roughness while turning 42CrMo4 steel using a carbide tool insert. Cutting parameters, such as spindle speed, feed, and depth of cut, were used. Signal processing is carried out using different techniques to identify the effect of the cutting parameters on vibration signals. Finally, we delve into the interaction effects between the cutting parameters, vibration signals and surface roughness, offering a comprehensive understanding of real-world manufacturing scenarios. Higher I-kaz3D coefficients correspond to higher surface roughness values. The I-kaz3D coefficient decreases as the surface roughness measurements decrease, indicating that the I-kaz3D technique can accurately indicate an increase or decrease in surface roughness. On the other hand, the cutting force Fc was the component most strongly correlated with surface roughness (Ra), yielding the best results across all indices (adjusted R²adj = 95.1%, er=.8 ± 2.3%).

In Vitro Evaluation Of Surface Roughness Of Three Class V Restorative Materials Following Prophylactic Instrumentation

Objective: This study was designed to determine which among the three Class V restorative materials - Omnichroma, GC Gold label Hybrid and Beautifil exhibits the least increase in surface roughness when subjected to manual or ultrasonic prophylactic instrumentation. Materials and methods: Class V cavity preparation were performed on 60 mandibular premolar teeth and randomly divided into 3 groups of 20 specimens each. They were restored with the assigned restorative material, i.e. Composite (Group 1), GIC (Group 2) and Giomer (Group 3). Restorations were finished and polished and then subjected to surface profilometry analysis for determining the surface roughness values followed by simulated aging by thermocycling. These groups were further subdivided into two subgroups consisting of 10 samples each and subjected to manual and ultrasonic prophylactic instrumentation followed by surface profilometric analysis. After polishing using prophylactic paste, once again surface profilometry analysis was done. The data thus obtained were subjected to statistical analysis using SPSS 26.0 (SPSS Inc., Chicago, IL) software. Results and discussion: The highest value for surface roughness was seen with Group 1 (Omnichroma) followed by Group 2 (GC Gold Label hybrid). Group 3 (Beautifil) exhibited lowest value for surface roughness along all the stages. Manual instrumentation groups showed increased surface roughness compared to ultrasonic instrumentation groups. Conclusion: Among the three tested materials, best surface finish at all stages of evaluation was seen with Beautifil, followed by GC Gold label hybrid and the lowest quality was seen with Omnichroma.

In Vitro Comparison of Titanium Disc Surface Roughness and Bacterial Colonization After Ultrasonic Instrumentation With Three Different Tips.

During implant maintenance, preserving a smooth surface on the machined transmucosal abutment is critical to reduce biofilm attachment and colonization. The present study compared the surface roughness and bacterial colonization of machined titanium surfaces after instrumentation with various materials. Forty-four machined grade 23 titanium discs were instrumented with a round polyether ether ketone (PEEK) tip, a plastic curette tip, or a pure titanium curette tip with piezoelectric devices. Before and after instrumentation, the surface roughness (Ra and Rz) values were analyzed with a profilometer and scanning electron microscopy (SEM). Streptococcus sanguinis was cultured and incubated for 24 hours on the instrumented discs, and colony-forming units per milliliter were obtained for each group. Samples instrumented with the metal ultrasonic tip significantly increased surface roughness compared with the other groups. This resulted in greater colonization by S. sanguinis than surfaces instrumented with PEEK tips or the negative control. Samples instrumented with PEEK and plastic tips did not exhibit any statistically significant increase in surface roughness, and SEM analysis revealed a significantly rougher surface of discs instrumented with metal compared with discs instrumented with plastic or PEEK tips despite the possibility of debris from tip dissolution. Our results suggest that instrumentation with metal ultrasonic tips with piezoelectric devices significantly increased machined titanium's surface roughness and elicited higher biofilm formation in vitro. Meanwhile, instrumentation of machined titanium with PEEK or plastic ultrasonic tips did not affect the surface roughness or bacterial adhesion.

Effect of Machining Parameters on the Surface Roughness of Hot Die Steel

H13 tool steel is frequently used in hot work dies, hot forging, hot extrusion, and mold materials for casting ferrous and nonferrous materials. Surface roughness is of key importance in case of dies and moulds, as it insures the finish of the final product. After studying the work done by the researchers in field of machining and its impact over surface roughness, it was found that machining behaviour of H13 steel at the annealed state is not being studied. The surface finish obtained during turning of H13 steel are not studied on a greater scale, so the present study includes the analysis of finish (surface roughness) generated. Turning operation is carried out on the CNC machine at dry condition with an aim to find systematically the effect on surface roughness by distinct machining variables like feed rate, depth of cut and speed. RSM model using Box Behnken design is used to predict the roughness developed during turning of annealed H13 steel using carbide tool. It was found that feed rate and the depth of cut have a direct relation with the surface finish and the value of surface roughness increases with increase in these parameters. On the other side, cutting speed has a less impact over the surface roughness & is inversely related.

Effect of sodium tungstate concentration on surface morphology and hardness variation of 6063 aluminium alloy using by plasma electrolytic oxidation

Abstract The coatings were prepared on the surface of 6063 aluminium alloy using by plasma electrolytic oxidation in a sodium tungstate (Na2WO4) electrolyte solution with concentration varying from 0.017 to 0.068 mol/L. The power of plasma electrolytic oxidation is about 600 W, electrolysis time is 20 and 30 minutes, respectively. In this study using sodium tungstate as the main component of the electrolyte without any additives. The effects of Na2WO4 concentrations on the surface morphology and hardness variation of the 6063 aluminium alloys are investigated. These oxide films on aluminium were characterized by laser scanning confocal microscope, scanning electron microscopy (SEM) and Vickers microhardness indenter (Hv), respectively. The results reveal Na2WO4 electrolyte solution with concentration varying from 0.017, 0.034, 0.051 to 0.068 mol/L. When the electrolyte concentration is 0.034 mol/L, the maximum hardness value is 104 Hv after plasma electrolytic oxidation for 20 minutes. When the electrolyte concentration is 0.051 mol/L, the minimum surface roughness value obtained by plasma electrolytic oxidation for 30 minutes is Sa 0.324 μm.

Impact of drilling parameters on the surface roughness of egg shell filled glass fibre/polyester composites

Abstract Glass fiber-reinforced polymers (GFRPs) are widely used in domestic applications such as doors, windows, and furniture, where drilling is a common machining process. The surface roughness of drilled hole walls is a critical factor, particularly in fastening applications, where smooth finishes are essential. This study explores the influence of drilling parameters on the surface roughness of GFRPs reinforced with different types of eggshell fillers viz.,un-carbonized, carbonized, and hybrid along with an unfilled variant. The research employs a Central Composite Design within the Response Surface Methodology (RSM) framework to investigate the effects of material type, spindle speed, feed rate, and point angle on surface roughness. Material type and point angle were treated as categorical variables, while spindle speed and feed rate were continuous, each with four levels, resulting in 16 experimental runs. The results showed that surface roughness values varied from 3.04 to 4.99μm, depending on the specific combination of drilling parameters. Statistical analysis using Analysis of Variance (ANOVA) confirmed that spindle speed and feed rate significantly impact surface roughness, with roughness increasing at higher speeds and feeds. Notably, the carbonized eggshell-filled GFRP variant achieved the lowest surface roughness. The study also developed a highly accurate regression model, validated through experimental data. The novel use of different variants of eggshell fillers in GFRPs provides a sustainable and effective way to enhance material properties. Further, conducting the drilling studies to observe the outcomes, offers potential industrial applications in the production of high-quality, durable composite materials.

Analysis of wettability and contact angle of sodium bicarbonate impregnated wooden surfaces

Scots pine and spruce wood samples were vacuum impregnated with 3, 5, and 9% sodium bicarbonate solution. Contact angle measurements were made by dropping 0.05 mL of pure water and 3% saltwater solution onto the material’s surface. The surface roughness of each sample was measured, and that of Scots pine control samples was higher than that of spruce samples, but the surface roughness values of spruce wood were higher in the samples impregnated with sodium bicarbonate. When pure water or saltwater solution was dropped onto the samples, it was observed that as the waiting times increased, the contact angle value decreased, the droplet height decreased, and the droplet width increased. It was found that the contact angles were higher in the control samples of both tree species than in the samples of 5% and 7%. The contact angles of 9% impregnation solution, pure water, and salt water were higher than the control samples. As the solution ratio increased on the surfaces impregnated with sodium bicarbonate, the contact angle also increased, and the wettability behavior decreased accordingly. Sodium bicarbonate solution is effectively used in the impregnation process for pine and fir woods, making the materials more resistant to water under outdoor conditions. This solution significantly reduces the risk of deformation of wood by increasing the contact angle and reducing its water absorption properties.

EVALUATING THE MARGINAL DISCREPANCY AND SURFACE ROUGHNESS OF CAD - CAM MILLED VS 3D PRINTED PROVISIONAL CROWNS - AN INVITRO STUDY

Aims &Objectives: To evaluate Marginal discrepancy and Surface roughness of CAD-CAM Milled and 3D Printed provisional crowns after subjecting them to thermocycling. Materials and Methods: A stainless-steel metal die with ANSI/ADA specifications had been fabricated for the study. It was scanned with an intraoral scanner and the data was sent to VHF S5M CAD CAM milling and R3Pro printing machine. A total of 10 samples Milled Group A(n=10) and 10 Printed Group B(n=10) provisional crowns were fabricated from PMMA material using the scanned data. The temperatures for thermocycling are 37ºC and 60ºC. Each group is subdivided into two subgroups(n=5) based on thermocycling temperatures. The timeduration selected for Thermocycling was 7,14 and21 days. Marginal discrepancy was measured by using Stereomicroscope and Surface roughness was measured with Profilometer. Results: Marginal discrepancy values were greater in CAD CAM milled crowns(141.47 µm) than in Printed crowns(109.87 µm) at 60ºC after a time-period of 21days.Surface roughness values were higher in Milled crowns(3.915µm) than in CAD CAM Printed crowns(3.817µm) at 60ºC for a given time duration of 21days. One-way ANOVA statistical analysis was done. The mean marginal gap of CAD CAM Milled crowns was statistically significant than Printed crowns(p>0.05). Conclusion: Printed provisional restorationshad better Marginal accuracythan CAD CAM Milled provisional crowns. Surface roughness was higher in CAD CAM Milled crowns than in Printed provisional restorations.

Corrosion Behavior of Nickel-Titanium Arch Wires Following the Use of Different Mouthwashes: An In Vivo Study.

The aim of this double-blind in vivo study was to compare the extent of corrosion on the surface of nickel-titanium (NiTi) wires in various mouthwashes. A total of 80 patients who received orthodontic treatment with as-received 0.016x0.022 inch NiTi wires were included in the study, and they were split into 4 groups. The first group used 0.05% of (225ppm F-) sodium fluoride (NaF) (Colgate Plax®) containing mouthwash, 21.6% alcohol (Listerine Cool Mint®) containing mouthwash, and 0.2% clorhexidine (CHX) (Klorhex®) containing mouthwash and the control group used drinking water with melt menthol as mouthwash. After 30 days of using mouthwash, the surfaces of NiTi wires were examined with atomic force microscopy (AFM), and surface roughness values were calculated. Mouthwashes containing fluoride, essential oils, and CHX created higher surface roughness on NiTi wires than the control group. The floride-containing mouthwash group showed less corrosion than the CHX group, whereas there was no difference between the essential oil group. AFM images show supportive data with the results of the clinical study. The results were assessed using a 95% confidence interval and a significance level p<0.05. CHX, essential oil, and floride-containing mouthwashes cause corrosion of NiTi wires. Floride-containing mouthwash can be preferred over CHX mouthwash due to its lesser corrosion effect.

INVESTIGATION OF WETTABILITY, ANTIBACTERIAL ACTIVITY, THERMAL INSULATION, AND MECHANICAL CHARACTERISTICS OF ELASTOMER BLEND ADHESIVES WITH HIGH-DENSITY FIBERBOARD WOOD AND ALUMINUM

Attention has recently been given to finding alternative and sustainable raw material sources for wood and metal adhesives, such as polyvinyl alcohol (PVA), corn starch (CS), arabic gum (AG), and dextrins (D). Modifying polymer dispersion using unique substances, such as modifying reactive elastomer liquid (EL) using PVA, CS, AG, or D results in sufficiently moisture-resistant adhesive joins. In the present study, the physical characteristics of EL/blended with the natural polymers PVA, CS, AG, and D, based on high-density fiberboard (HDF) wood and aluminum (Al) adhesives and coatings, were investigated and compared to those of pure EL. The EL was blended with PVA, CS, AG, or D at a ratio of 60/40 (w/w) to form EL/blends. The chemical structures, surface and interface morphology, adhesion strengths (including shear strength and pull-off strength), surface roughness, wettings, color intensity, and thermal insulation of the prepared EL and EL/blends were investigated. A scanning electron microscopy (SEM) investigation confirmed filler dispersion and adhesion between the blends, and coated HDF wood, or Al. The developed EL/AG blend had a pull-off strength of 144±5 and 102±3 MPa and a shear strength of 771±11, and 52±3 N with HDF wood and Al substrate, respectively. The EL/PVA blend had a maximum surface roughness value 4.57 µm, and its average water contact angle (WCA) was 85.6°. A plasma jet was used to treat the surface roughness and hence the wettability of the pure EL and the EL/blends, for example, plasma treatment decreased the roughness of the EL/AG blend from 4.36 to 3.28 μm. WCA, and hence wettability, was also significantly influenced by plasma treatment, for example, plasma treatment decreased the WCA of the pure EL from 71.7±0.4° to 30.7±0.7°. The lightness value of the EL/blends was less than that of the pure EL, indicating that (the color adhesives have darkened). Similarly, the yellowness-blueness and redness-greenness values of the EL/blends were greater than those of the pure EL,( rendering the blended adhesives more reddish and bluish). The EL/AG blend was found to have a minimum thermal conductivity (of 0.27 W/m.K), indicating maximum insulation.

Effect of Hydrogen Peroxide-Based Bleaching Agents on the Color Dimensions and Surface Roughness of Different Milled Restorative Dental Materials.

To compare the color dimensions, color discrepancies (ΔE00), and surface roughness of milled materials before and after application of a bleaching agent. A total of 10 extracted molars were obtained. Each tooth was cut in transverse sections to create disks (3-mm thick, 10-mm diameter; control group). Disk specimens of eight materials (n &#61; 10 per group) were fabricated: polymethyl methacrylate (PMMA) interim material (PMMA-Telio group), two resin nanoceramics (RNC-Ultimate group and RNC-Cerasmart group), two hybrid ceramics (HC-Shofu group and HC-Enamic group), lithium disilicate (LD-Emax group), zirconia-reinforced glass ceramic (ZGC-Suprinity group), and zirconia (Zr-InCeram group). Color measurements were obtained using a spectrophotometer before and after applying 35% hydrogen peroxide-based bleaching agent. Pre- and postbleaching surface roughness (Sa) analyses were completed using a profilometer. Significant L*, a*, b*, and ΔE00 value differences were found (P < .05). Color discrepancies (ΔE00) ranged from 0.30 ± 0.14 to 4.82 ± 0.10. The highest color discrepancies were measured on the PMMA-Telio group, while the lowest color discrepancies were computed for ZGC-Suprinity, RNCUltimate, and RNC-Cerasmart. Significant surface roughness differences were found (P < .05). The largest increase of surface roughness values between the pre- and postbleaching measurements was obtained in the PMMA-Telio group with a mean ΔSa value of 4.73 ± 3.02, while the largest decrease of surface roughness values between the pre- and postbleaching measurements was obtained in the Zr-InCeram group with a mean ΔSa value of -1.58 ± 0.10. The milled materials showed significant pre- and postbleaching color and surface roughness discrepancies.

Pulsed Unipolar-Polarisation Plasma Electrolytic Polishing of Ni-Based Superalloys: A Proof of Conception

The enhanced performance of aerospace equipment drives parts development towards integration, complexity, and structural optimization. This advancement promotes metal near-net fabrication technologies like wire electrical discharge machining (WEDM) and 3D printing. However, the high initial surface roughness from WEDM or 3D printing poses significant challenges for the high-performance surface finishing required. To effectively reduce the surface roughness of the workpieces with high initial surface roughness, this paper proposes pulsed unipolar-polarisation plasma electrolytic polishing (PUP-PEP). The study examined the material removal mechanisms and surface polishing quality of PUP-PEP. This technique combines the high current density and material removal rate of the electrolytic polishing mode with the superior surface polishing quality of PEP through voltage waveform modulation. For an Inconel-718 superalloy part fabricated by WEDM, PUP-PEP reduced surface roughness from Ra 7.39 μm to Ra 0.27 μm in 6 min under optimal conditions. The roughness decreased from Ra 7.39 μm to Ra 0.78 μm in the first 3 min under pulsed unipolar-polarisation voltage, resulting in a remarkable 233% increase in efficiency compared to that with conventional PEP. Subsequently, the voltage output voltage is transformed into a constant voltage mode, and PEP is continued based on PUP-PEP to finally reduce the workpiece surface roughness value to Ra 0.27 μm. The proposed PUP-PEP technology marks the implementation of ‘polishing’ instead of conventional rough-finish machining processes, presenting a new approach to the surface post-processing of metal near-net fabrication technologies.

Investigating the erosive wear characteristics of AISI 420 martensitic stainless steel after surface hardening by boriding

Erosive wear degrades industrial components, causing surface deterioration and material loss. Understanding and mitigating this wear enhances component longevity and efficiency. Little research has been conducted to investigate the influence of particle angle, speed, and concentration on boronized surfaces. Therefore, in this study, the erosive wear behaviors of raw and boronized AISI 420 martensitic stainless steels were investigated. The samples were subjected to erosive wear testing using SiO2 abrasive particles with impact velocities of 2, 4, and 6 m/s, impact angles of 30°, 60°, and 90°, and concentration values of 5%, 10%, and 15% by weight in an abrasive sand slurry environment. Experimental runs were designed using the Taguchi L9 method. The wear test results were analyzed in terms of mass loss, surface roughness, and temperature change of the boronized and raw AISI 420 samples before and after the test. The results showed that the impact speed and concentration were statistically significant parameters compared with the impact angle, which had a negligible effect. Furthermore, with increasing impact speed and concentration, all measured responses increased in both sample groups. The surface roughness values and mass loss increased by lower margins for the boronized samples (58.40% and 188.49%, respectively) compared to those of the raw samples (61.40% and 254.38%, respectively). This study demonstrates the potential of boriding as a surface treatment technique for enhancing the erosive wear performance of martensitic stainless steels, which require improved durability and longevity of materials subjected to erosive environments.

Effect of drill gash rake angle on drillability in plain carbon and low alloy steels

In this study, the effects of the gash rake angle (γa), which is an important component of the drill geometry, on the thrust force and drilling torque occurring in the drilling of ordinary carbon steels (AISI 4140 and Ck 45) were examined through experimental and FEM-supported numerical simulation studies on surface roughness, tool surface roughness, wear and diameter deviation values were investigated experimentally. In the experiments, 6.8 mm diameter solid cementite carbide, coated and internal cooling channel drills with +10°, 0°, −10° gash rake angle were used. Three different feed rates and cutting speed levels were selected as cutting parameters. Determination of material-specific gash rake angle and cutting parameters for different materials was carried out by Taguchi-assisted variance analysis of experimental data. In experimental studies, the gash rake angle was 65.9% effective on the thrust force for AISI 4140 tempered steel, while it was the second effective parameter with 29.22% for Ck 45 manufacturing steel. While the feed rate is the more effective parameter in the drilling moments that occur when drilling different materials, it has been observed that γa also has a significant effect. It has been determined that chisel edge wear, main cutting edge wear and crater wear occur in the drill when drilling AISI 4140 tempered steel and Ck 45 manufacturing steel. The data obtained from the finite element-assisted chip removal analyses support the experimental results and provide guiding results in the selection of material-specific gash rake angle.

ANALYSIS AND OPTIMIZATION OF PROCESS PARAMETERS AFFECTING FORM ERRORS AND SURFACE ROUGHNESS IN MILLING OF AGING-TREATED AA 6063-T6 FREE FORM SURFACES

This study aimed to explore the microstructure and hardness changes in AA 6063 T6 specimens that underwent an ageing procedure. The second portion involves the machining of free forms surfaces on specimens with varying microstructures and hardness. Four distinct tool paths, four varied Vcs, and four diverse fs were employed in the machining of the surfaces. Statistical analysis were conducted to ascertain the optimal cutting parameters and their impact on the output parameters. The experimental design was designed based on the Taguchi L16 index. The form errors and surface roughness values acquired from the tests were analysed statistically using the Signal/Noise (S/N) ratio and analysis of variance (ANOVA) methods. The study found that the sample immersed in 2WQ solution had a minimum hardness value of 71.7 Hv1, whereas the sample aged for 18 hours had a maximum hardness value of 117.7 Hv1. Based on the investigation, it was determined that A4B1C4 yielded the most favourable cutting parameter in terms of form error and surface roughness. This refers to the utilisation of the TP4 tool path, a f of 0.04 mm per tooth, and a Vc of 105 m/min. Based on the data collected, the ANOVA analysis of the 18AQ sample revealed that the cutting parameters with the highest efficacy in minimising form error and surface roughness were a f of 51.18% and 59.07%, respectively. These values represent the optimum values for cutting parameters.

Experimental Study on Dry Milling of Stir-Casted and Heat-Treated Mg-Gd-Y-Er Alloy Using TOPSIS

This study examines the dry milling process of a rare-earth-based magnesium alloy, emphasizing the optimization of the milling parameters and their impact on the surface quality, cutting forces, and the rate of material removal. The objective is to improve our comprehension of the milling behavior of the Mg-Gd-Y-Er alloy. The Taguchi technique is adopted to formulate the experimental design. This study methodically investigates the influence of heat treatment (T4 and T6) on milling performance, and the effects of speed, feed rate, and depth of cut. The output variables considered for this investigation are the surface roughness (Ra, Rz, Sa, and Sz), material removal rate (MRR), and cutting force. To optimize the milling parameters and achieve superior outcomes, the multi-objective optimization technique TOPSIS is used. At a feed rate of 150 mm/min, a spindle speed of 1500 rpm, and a depth of cut of 1 mm, the T4-treated sample exhibits a minimum surface roughness value of 0.0305 µm. The highest resultant force values of 96.4416 N and 176.1070 N for 200 °C and 225 °C T6-treated alloys are obtained by combining process parameters such as a spindle speed of 1500 rpm, a feed rate of 50 mm/min, and a depth of cut of 1.5 mm. Furthermore, the maximum closeness coefficient value is achieved by combining a spindle speed of 1000 to 1500 rpm, a feed rate of 150 mm/min, and a depth of cut of 0.5 mm to 1 mm. The closeness coefficient value is significantly influenced by the most significant process parameters, as indicated by the ANOVA results.

Prediction of surface roughness at the machining of densified wood surfaces

ABSTRACT In this research, modeling and interpretation of the effects of the machining parameters on surface roughness (Rz) using artificial neural networks (ANN) and analysis methods (MLP, LVQ and Taguchi Design analysis) werw studied. Black poplar (Populus nigra) was selected as the experimental material. Specimens, which were transversal densified by a thermo-mechanical (TM) process at 0%, 20% and 40% compression ratios. The densified wood was processed at 1000, 1500 and 2000 mm/min feed speeds and in 12,000, 15,000, and 18,000 rpm rotation speeds in a CNC machine by using two different cutters. Rz surface-roughness values were measured. The modeling of Rz with artificial neural networks (ANN) is discussed. While 97% success was achieved in the classification made with multilayer perceptron (MLP) in estimating Rz, this success rate is 100% in the classification made with learning vector quantization (LVQ). MLP and LVQ are operations in the MATLAB R2019b software. Taguchi values were compared with the experimental data results, it was seen that the MSE value was 4.6%, the MAE value was 1.8%, and the RMSE value was 2.1%. These results showed that the presented models can accurately determine the appropriate parameters for the desired Rz. The prediction results and presented models can be applied for targeted industrial applications.

An investigation of dynamic droplet wetting within the smoothed dissipative particle dynamics (SDPD) multi-scale modeling framework

The multi-scale numerical procedure proposed in our previous work based on smoothed dissipative particle dynamics (SDPD) is employed, and a new multi-phase interaction model based on the inter-particle force (IPF) that includes a consistent repulsion force is presented and verified. A comparative investigation utilizing smoothed particle hydrodynamics (SPH), SDPD, and our multi-scale methods is then carried out and the computational efficiency, droplet morphology, wetting flow field, and advantages of the multi-scale method are demonstrated. In addition, the droplet thickness is derived from the Navier–Stokes equations with a stochastic force, demonstrating the effect of thermal fluctuations on the mesoscopic scale. Finally, the wetting states are simulated at different surface roughness values, and the transition of states and some new mechanisms are clarified. When the roughness scale is smaller than the interaction range between particles, the wetting state may change significantly, and this effect becomes weaker when the roughness scale exceeds the interaction range. The results also show that the horizontal roughness (direction of droplet spreading) is more decisive than vertical one (perpendicular to the direction of droplet spreading), usually leading to a transition of the wetting states, while the vertical roughness usually plays a reinforcing role.

Impact of Toolpath Pitch Distance on Cutting Tool Nose Radius Deviation and Surface Quality of AISI D3 Steel Using Precision Measurement Techniques.

The selection of the right tool path trajectory and the corresponding machining parameters for end milling is a challenge in mold and die industries. Subsequently, the selection of appropriate tool path parameters can reduce overall machining time, improve the surface finish of the workpiece, extend tool life, reduce overall cost, and improve productivity. This work aims to establish the performance of end milling process parameters and the impact of trochoidal toolpath parameters on the surface finish of AISI D3 steel. It especially focuses on the effect of the tool tip nose radius deviation on the surface quality using precision measurement techniques. The experimental design was carried out in a systematic manner using a face-centered central composite design (FCCD) within the framework of response surface methodology (RSM). Twenty different experiment trials were conducted by changing the independent variables, such as cutting speed, feed rate, and trochoidal pitch distance. The main effects and the interactions of these parameters were determined using analysis of variance (ANOVA). The optimal conditions were identified using a multiple objective optimization method based on desirability function analysis (DFA). The developed empirical models showed statistical significance with the best process parameters, which include a feed rate of 0.05 m/tooth, a trochoidal pitch distance of 1.8 mm, and a cutting speed of 78 m/min. Further, as the trochoidal pitch distance increased, variations in the tool tip cutting edge were observed on the machined surface due to peeling off of the coating layer. The flaws on the tool tip, which alter the edge micro-geometry after machining, resulted in up to 33.83% variation in the initial nose radius. Deviations of 4.25% and 5.31% were noted between actual and predicted values of surface roughness and the nose radius, respectively.