Search results for: aerodynamic roughness length

Authors: Mohd Izmir Bin Yamin, Thomas Arthur Ward

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Past aerodynamic studies of flapping wing flight have shown that it has increased aerodynamic performances compared to fixed wing steady flight. One of the dominant mechanisms that is responsible for causing this phenomenon is a leading edge vortex, generated by the flapping motion of a flexible wing. Wind tunnel experiments were conducted to observe the aerodynamic profile of a flapping wing, by measuring the lift, drag and thrust. Analysis was done to explain how unsteady aerodynamics leads towards better power performances than a fixed wing flight. The information from this study can be used as a base line for designing future Bio-mimetic Micro Air Vehicles that are based on flying insect aerodynamic mechanisms.

Keywords: flapping wing flight, leading edge vortex, aerodynamics performances, wind tunnel test

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Authors: R. Noorani, K. Peerless, J. Mandrell, A. Lopez, R. Dalberto, M. Alzebaq

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Rapid prototyping (RP) is an additive manufacturing technology used in industry that works by systematically depositing layers of working material to construct larger, computer-modeled parts. A key challenge associated with this technology is that RP parts often feature undesirable levels of surface roughness for certain applications. To combat this phenomenon, an experimental technique called Design of Experiments (DOE) can be employed during the growth procedure to statistically analyze which RP growth parameters are most influential to part surface roughness. Utilizing DOE to identify such factors is important because it is a technique that can be used to optimize a manufacturing process, which saves time, money, and increases product quality. In this study, a four-factor/two level DOE experiment was performed to investigate the effect of temperature, layer thickness, infill percentage, and infill speed on the surface roughness of RP prototypes. Samples were grown using the sixteen different possible growth combinations associated with a four-factor/two level study, and then the surface roughness data was gathered for each set of factors. After applying DOE statistical analysis to these data, it was determined that layer thickness played the most significant role in the prototype surface roughness.

Keywords: rapid prototyping, surface roughness, design of experiments, statistical analysis, factors and levels

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Authors: Wei Zhang, Yan He, Yan Wang, Yufeng Li, Chuanpeng Hao

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Surface roughness is an important index for evaluating surface quality, needs to be accurately measured to ensure the performance of the workpiece. The roughness measurement based on machine vision involves various image features, some of which are redundant. These redundant features affect the accuracy and speed of the visual approach. Previous research used correlation analysis methods to select the appropriate features. However, this feature analysis is independent and cannot fully utilize the information of data. Besides, blindly reducing features lose a lot of useful information, resulting in unreliable results. Therefore, the focus of this paper is on providing a redundant feature removal approach for visual roughness measurement. In this paper, the statistical methods and gray-level co-occurrence matrix(GLCM) are employed to extract the texture features of machined images effectively. Then, the principal component analysis(PCA) is used to fuse all extracted features into a new one, which reduces the feature dimension and maintains the integrity of the original information. Finally, the relationship between new features and roughness is established by the support vector machine(SVM). The experimental results show that the approach can effectively solve multi-feature information redundancy of machined surface images and provides a new idea for the visual evaluation of surface roughness.

Keywords: feature analysis, machine vision, PCA, surface roughness, SVM

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Authors: Siti Ruhliah Lizarose Samion, Mohamed Sukri Mat Ali

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The effect of sawtooth plate thickness on the aerodynamic noise generated in flow at a Reynolds number of 150 is numerically investigated. Two types of plate thickness (hthick=0.2D and hthin=0.02D) are proposed. Flow simulations are carried out using Direct Numerical Simulation, whereas the calculation of aerodynamic noise radiated from the flow is solved using Curle’s equation. It is found that the flow behavior of thin sawtooth plate, consisting counter-rotating-vortices, is more complex than that of the thick plate. This then explains well the generated sound in both plates cases. Sound generated from thin plat is approximately 0.5 dB lower than the thick plate. Findings from current study provide better understanding of the flow and noise behavior in edge serrations via understanding the case of a sawtooth plate.

Keywords: aerodynamic sound, bluff body, sawtooth plate, Curle analogy

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Authors: Tugba Bayoglu

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Aerodynamic parameter estimation is very crucial in missile design phase, since accurate high fidelity aerodynamic model is required for designing high performance and robust control system, developing high fidelity flight simulations and verification of computational and wind tunnel test results. However, in literature, there is not enough missile aerodynamic parameter identification study for three main reasons: (1) most air to air missiles cannot fly with constant speed, (2) missile flight test number and flight duration are much less than that of fixed wing aircraft, (3) variation of the missile aerodynamic parameters with respect to Mach number is higher than that of fixed wing aircraft. In addition to these challenges, identification of aerodynamic parameters for high wind angles by using classical estimation techniques brings another difficulty in the estimation process. The reason for this, most of the estimation techniques require employing polynomials or splines to model the behavior of the aerodynamics. However, for the missiles with a large variation of aerodynamic parameters with respect to flight variables, the order of the proposed model increases, which brings computational burden and complexity. Therefore, in this study, it is aimed to solve nonlinear aerodynamic parameter identification problem for a supersonic air to air missile by using Artificial Neural Networks. The method proposed will be tested by using simulated data which will be generated with a six degree of freedom missile model, involving a nonlinear aerodynamic database. The data will be corrupted by adding noise to the measurement model. Then, by using the flight variables and measurements, the parameters will be estimated. Finally, the prediction accuracy will be investigated.

Keywords: air to air missile, artificial neural networks, open loop simulation, parameter identification

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Authors: Hyeong-Jin Kim, Jong Kook Lee

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Zirconia has biological, mechanical and optical properties, so, it used as a dental implant material in human body. But, it is difficult to form directly bonding with living tissues after the procedure and induces the falling away from implanted parts of the body. To improve this phenomenon, it is essential to increase the surface roughness of zirconia implants and induce a forming-ability of strong bonds. In this study, we performed a room temperature spray coating on zirconia specimen to obtain a highly roughened zirconia surface. To get optimal surface roughness, we controlled the distance between the nozzle and the substrate, coating times and powder condition. Bonding microstructure, surface roughness, and chemical composition of the coating layer were observed by SEM, XRD and roughness tester.

Keywords: implant, aerosoldeposition, zirconia, dental

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Authors: Diego F. Camacho, Cristian J. Mejia, Carlos Duque-Daza

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The recent widespread use of Unmanned Aerial Vehicles (UAVs) has fueled a renewed interest in efficiency and performance of airfoils, particularly for applications at low and moderate Reynolds numbers, typical of this kind of vehicles. Most of previous efforts in the aeronautical industry, regarding aerodynamic efficiency, had been focused on high Reynolds numbers applications, typical of commercial airliners and large size aircrafts. However, in order to increase the levels of efficiency and to boost the performance of these UAV, it is necessary to explore new alternatives in terms of airfoil design and application of drag reduction techniques. The objective of the present work is to carry out the analysis and comparison of performance levels between a standard NACA0012 profile against another one featuring a wall protuberance or surface perturbation. A computational model, based on the finite volume method, is employed to evaluate the effect of the presence of geometrical distortions on the wall. The performance evaluation is achieved in terms of variations of drag and lift coefficients for the given profile. In particular, the aerodynamic performance of the new design, i.e. the airfoil with a surface perturbation, is examined under conditions of incompressible and subsonic flow in transient state. The perturbation considered is a shaped protrusion prescribed as a small surface deformation on the top wall of the aerodynamic profile. The ultimate goal by including such a controlled smooth artificial roughness was to alter the turbulent boundary layer. It is shown in the present work that such a modification has a dramatic impact on the aerodynamic characteristics of the airfoil, and if properly adjusted, in a positive way. The computational model was implemented using the unstructured, FVM-based open source C++ platform OpenFOAM. A number of numerical experiments were carried out at Reynolds number 5x104, based on the length of the chord and the free-stream velocity, and angles of attack 6° and 12°. A Large Eddy Simulation (LES) approach was used, together with the dynamic Smagorinsky approach as subgrid scale (SGS) model, in order to account for the effect of the small turbulent scales. The impact of the surface perturbation on the performance of the airfoil is judged in terms of changes in the drag and lift coefficients, as well as in terms of alterations of the main characteristics of the turbulent boundary layer on the upper wall. A dramatic change in the whole performance can be appreciated, including an arguably large level of lift-to-drag coefficient ratio increase for all angles and a size reduction of laminar separation bubble (LSB) for a twelve-angle-of-attack.

Keywords: CFD, LES, Lift-to-drag ratio, LSB, NACA 0012 airfoil

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Authors: Zhengkun Yi

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Surface texture discrimination using artificial tactile sensors has attracted increasing attentions in the past decade as it can endow technical and robot systems with a key missing ability. However, as a major component of texture, roughness has rarely been explored. This paper presents an approach for tactile surface roughness discrimination, which includes two parts: (1) design and fabrication of a bioinspired artificial fingertip, and (2) tactile signal processing for tactile surface roughness discrimination. The bioinspired fingertip is comprised of two polydimethylsiloxane (PDMS) layers, a polymethyl methacrylate (PMMA) bar, and two perpendicular polyvinylidene difluoride (PVDF) film sensors. This artificial fingertip mimics human fingertips in three aspects: (1) Elastic properties of epidermis and dermis in human skin are replicated by the two PDMS layers with different stiffness, (2) The PMMA bar serves the role analogous to that of a bone, and (3) PVDF film sensors emulate Meissner’s corpuscles in terms of both location and response to the vibratory stimuli. Various extracted features and classification algorithms including support vector machines (SVM) and k-nearest neighbors (kNN) are examined for tactile surface roughness discrimination. Eight standard rough surfaces with roughness values (Ra) of 50 μm, 25 μm, 12.5 μm, 6.3 μm 3.2 μm, 1.6 μm, 0.8 μm, and 0.4 μm are explored. The highest classification accuracy of (82.6 ± 10.8) % can be achieved using solely one PVDF film sensor with kNN (k = 9) classifier and the standard deviation feature.

Keywords: bioinspired fingertip, classifier, feature extraction, roughness discrimination

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Authors: R. Sarjahani, M. Sheikhattar, S. Javadpour, B. Hashemi

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Glazes and their surface characterization is an important subject for ceramic industries. Fabrication of a super smooth surface resistant to stains is a big improvement for those industries. In this investigation, surface topography of popular glazes such as Zircon and Titania based opaque glazes, calcium based matte glaze and transparent glaze has been analyzed by Marsurf M300, SEM, EDS and XRD. Results shows that surface roughness of glazes seriously depends on surface crystallinity, crystal size and shapes.

Keywords: crystallinity, glaze, surface roughness, topography

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Authors: Muhammad Azhar, Arshad Hussain

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Vehicular emissions have increased in recent years due to rapid growth in world traffic resulting in an increase in associated problems such as air pollution and climate change, therefore it’s necessary to control vehicle emissions. This study looks at the effect of road maintenance on vehicle emissions. The Highway Development and Management Tool (HDM-4) was used to find the effect of road maintenance on vehicle emissions. Key data collected were traffic volume and composition, vehicle characteristics, pavement characteristics and climate data of the study area. Two options were analysed using the HDM-4 software; the base case or do nothing while the second is overlay maintenance. The study also showed a strong correlation between average roughness and yearly emission levels in both the alternatives. Finally, the study showed that proper maintenance reduces the roughness and emissions.

Keywords: vehicle emissions, road roughness, IRI, maintenance, HDM-4, CO2

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Authors: S. M. A. Al Qawabah, A. I. O. Zaid

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Al-4%Cu alloys are now widely used in many engineering applications especially in robotic, aerospace and vibration control area. The main problem arises from the weakness of their mechanical characteristics. Therefore, this study is directed towards enhancing the mechanical properties through severe plastic deformation. In this work, the hot direct extrusion process was chosen to provide the required hot work for this purpose. A direct extrusion die was designed and manufactured to be used in this investigation. The general microstructure, microhardness, surface roughness, and compression tests were performed on specimens from the produced Al-4%Cu alloy both in the as cast and after extrusion conditions. It was found that a pronounced enhancement in the mechanical characteristics of the produced Al-4%Cu after extrusion was achieved. The microhardness increased by 89.3%, the flow stress was decreased by 10% at 0.2 strain and finally the surface roughness was reduced by 81.6%.

Keywords: aluminum, copper, surface roughness, hot extrusion

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Authors: Youb Said, Fourar Ali

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To describe the influence of bottom roughness on the free surface flows by numerical modeling, a two-dimensional model was developed. The equations of continuity and momentum (Naviers Stokes equations) are solved by the finite volume method. We considered a turbulent flow in an open channel with a bottom roughness. For our simulations, the K-ε model was used. After setting the initial and boundary conditions and solve the equations set, we were able to achieve the following results: vortex forming in the hollow causing substantial energy dissipation in the obstacle areas that form the bottom roughness. The comparison of our results with experimental ones shows a good agreement in terms of the results in the rough area. However, in other areas, differences were more or less important. These differences are in areas far from the bottom, especially the free surface area just after the bottom. These disagreements are probably due to experimental constants used by the k-ε model.

Keywords: modeling, free surface flow, turbulence, bottom roughness, finite volume, K-ε model, energy dissipation

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Authors: J. Hajnys, M. Pagac, J. Petru, P. Stefek, J. Mesicek, J. Kratochvil

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The new progressive method of 3D metal printing SLM (Selective Laser Melting) is increasingly expanded into the normal operation. As a result, greater demands are placed on the surface quality of the parts produced in this way. The article deals with research of selected finishing methods (tumbling, face milling, sandblasting, shot peening and brushing) and their impact on the final surface roughness. The 20 x 20 x 7 mm produced specimens using SLM additive technology on the Renishaw AM400 were subjected to testing of these finishing methods by adjusting various parameters. Surface parameters of roughness Sa, Sz were chosen as the evaluation criteria and profile parameters Ra, Rz were used as additional measurements. Optical measurement of surface roughness was performed on Alicona Infinite Focus 5. An experiment conducted to optimize the surface roughness revealed, as expected, that the best roughness parameters were achieved through a face milling operation. Tumbling is particularly suitable for 3D printing components, as tumbling media are able to reach even complex shapes and, after changing to polishing bodies, achieve a high surface gloss. Surface quality after tumbling depends on the process time. Other methods with satisfactory results are shot peening and tumbling, which should be the focus of further research.

Keywords: additive manufacturing, selective laser melting, SLM, surface roughness, stainless steel

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Authors: Michael K.O. Ayomoh, Khaled A. Abou-El-Hossein., Sameh F.M. Ghobashy

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This paper proposes a numerical modelling scheme for surface roughness prediction. The approach is premised on the use of 3D difference analysis method enhanced with the use of feedback control loop where a set of adaptive weights are generated. The surface roughness values utilized in this paper were adapted from [1]. Their experiments were carried out using S55C high carbon steel. A comparison was further carried out between the proposed technique and those utilized in [1]. The experimental design has three cutting parameters namely: depth of cut, feed rate and cutting speed with twenty-seven experimental sample-space. The simulation trials conducted using Matlab software is of two sub-classes namely: prediction of the surface roughness readings for the non-boundary cutting combinations (NBCC) with the aid of the known surface roughness readings of the boundary cutting combinations (BCC). The following simulation involved the use of the predicted outputs from the NBCC to recover the surface roughness readings for the boundary cutting combinations (BCC). The simulation trial for the NBCC attained a state of total stability in the 7th iteration i.e. a point where the actual and desired roughness readings are equal such that error is minimized to zero by using a set of dynamic weights generated in every following simulation trial. A comparative study among the three methods showed that the proposed difference analysis technique with adaptive weight from feedback control, produced a much accurate output as against the abductive and regression analysis techniques presented in this.

Keywords: Difference Analysis, Surface Roughness; Mesh- Analysis, Feedback control, Adaptive weight, Boundary Element

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Authors: Misarah Abdelaziz, L Djenidi, Mergen H. Ghayesh, Rey Chin

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Measurements of a turbulent boundary layer over 3D sinusoidal roughness are performed for friction Reynolds numbers ranging from 650 < Reτ < 2700. This surface was fabricated by a Multicam CNC Router machine of an acrylic sheet to have an amplitude of k/2 = 0.8 mm and an equal wavelength of 8k in both streamwise and spanwise directions, a 0.6 mm stepover and 12 mm ball nose cutter was used. Single hotwire anemometry measurements are done at one location x=1.5 m downstream at different freestream velocities under zero-pressure gradient conditions. As expected, the roughness causes a downward shift on the wall-unit normalised streamwise mean velocity profile when compared to the smooth wall profile. The shift is increasing with increasing Reτ, 1.8 < ∆U+ < 6.2. The coefficient of friction is almost constant at all cases Cf = 0.0042 ± 0.0002. The results show a gradual reduction in the inner peak of profiles with increasing Reτ until fully destruction at Reτ of 2700.

Keywords: hotwire, roughness, TBL, ZPG

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Authors: Alexander Buhr, Klaus Ehrenfried

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Trackside induced airflow velocities, also known as slipstream velocities, are an important criterion for the design of high-speed trains. The maximum permitted values are given by the Technical Specifications for Interoperability (TSI) and have to be checked in the approval process. For train manufactures it is of great interest to know in advance, how new train geometries would perform in TSI tests. The Reynolds number in moving model experiments is lower compared to full-scale. Especially the limited model length leads to a thinner boundary layer at the rear end. The hypothesis is that the boundary layer rolls up to characteristic flow structures in the train wake, in which the maximum flow velocities can be observed. The idea is to enlarge the boundary layer using roughness elements at the train model head so that the ratio between the boundary layer thickness and the car width at the rear end is comparable to a full-scale train. This may lead to similar flow structures in the wake and better prediction accuracy for TSI tests. In this case, the design of the roughness elements is limited by the moving model rig. Small rectangular roughness shapes are used to get a sufficient effect on the boundary layer, while the elements are robust enough to withstand the high accelerating and decelerating forces during the test runs. For this investigation, High-Speed Particle Image Velocimetry (HS-PIV) measurements on an ICE3 train model have been realized in the moving model rig of the DLR in Göttingen, the so called tunnel simulation facility Göttingen (TSG). The flow velocities within the boundary layer are analysed in a plain parallel to the ground. The height of the plane corresponds to a test position in the EN standard (TSI). Three different shapes of roughness elements are tested. The boundary layer thickness and displacement thickness as well as the momentum thickness and the form factor are calculated along the train model. Conditional sampling is used to analyse the size and dynamics of the flow structures at the time of maximum velocity in the train wake behind the train. As expected, larger roughness elements increase the boundary layer thickness and lead to larger flow velocities in the boundary layer and in the wake flow structures. The boundary layer thickness, displacement thickness and momentum thickness are increased by using larger roughness especially when applied in the height close to the measuring plane. The roughness elements also cause high fluctuations in the form factors of the boundary layer. Behind the roughness elements, the form factors rapidly are approaching toward constant values. This indicates that the boundary layer, while growing slowly along the second half of the train model, has reached a state of equilibrium.

Keywords: boundary layer, high-speed PIV, ICE3, moving train model, roughness elements

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Authors: Mohammed T. Hayajneh, Adel Mahmood Hassan, Moath AL-Qudah

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Burnishing is increasingly used as a finishing operation to improve surface roughness and surface hardness. This can be achieved by applying a hard ball or roller onto metallic surfaces under pressure, in order to achieve many advantages in the metallic surface. In the present work, the feed rate, speed and force have been considered as the basic burnishing parameters to study the surface roughness and surface hardness of metallic matrix composites. The considered metal matrix composites were made from Aluminum-Magnesium-Graphite with five different weight percentage of graphite. Both effects of burnishing parameters mentioned above and the graphite percentage on the surface hardness and surface roughness of the metallic matrix composites were studied. The results of this investigation showed that the surface hardness of the metallic composites increases with the increase of the burnishing force and decreases with the increase in the burnishing feed rate and burnishing speed. The surface roughness of the metallic composites decreases with the increasing of the burnishing force, feed rate, and speed to certain values, then it starts to increase. On the other hand, the increase in the weight percentage of the graphite in the considered composites causes a decrease in the surface hardness and an increase in the surface roughness.

Keywords: burnishing process, Al-Mg-Graphite composites, surface hardness, surface roughness

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Authors: Ola Elfmark, Lars M. Bardal, Luca Oggiano, H˚avard Myklebust

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Team pursuit is a relatively new event in international long track speed skating. For a single speed skater the aerodynamic drag will account for up to 80% of the braking force, thus reducing the drag can greatly improve the performance. In a team pursuit the interactions between athletes in near proximity will also be essential, but is not well studied. In this study, systematic measurements of the aerodynamic drag, body posture and relative positioning of speed skaters have been performed in the low speed wind tunnel at the Norwegian University of Science and Technology, in order to investigate the aerodynamic interaction between two speed skaters. Drag measurements of static speed skaters drafting, leading, side-by-side, and dynamic drag measurements in a synchronized and unsynchronized movement at different distances, were performed. The projected frontal area was measured for all postures and movements and a blockage correction was performed, as the blockage ratio ranged from 5-15% in the different setups. The static drag measurements where performed on two test subjects in two different postures, a low posture and a high posture, and two different distances between the test subjects 1.5T and 3T where T being the length of the torso (T=0.63m). A drag reduction was observed for all distances and configurations, from 39% to 11.4%, for the drafting test subject. The drag of the leading test subject was only influenced at -1.5T, with the biggest drag reduction of 5.6%. An increase in drag was seen for all side-by-side measurements, the biggest increase was observed to be 25.7%, at the closest distance between the test subjects, and the lowest at 2.7% with ∼ 0.7 m between the test subjects. A clear aerodynamic interaction between the test subjects and their postures was observed for most measurements during static measurements, with results corresponding well to recent studies. For the dynamic measurements, the leading test subject had a drag reduction of 3% even at -3T. The drafting showed a drag reduction of 15% when being in a synchronized (sync) motion with the leading test subject at 4.5T. The maximal drag reduction for both the leading and the drafting test subject were observed when being as close as possible in sync, with a drag reduction of 8.5% and 25.7% respectively. This study emphasize the importance of keeping a synchronized movement by showing that the maximal gain for the leading and drafting dropped to 3.2% and 3.3% respectively when the skaters are in opposite phase. Individual differences in technique also appear to influence the drag of the other test subject.

Keywords: aerodynamic interaction, drag force, frontal area, speed skating

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Authors: Alonggot Limcharoen Kaeochotchuangkul, Pathomporn Sawatchai

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This research aims to design and build a wet etching system, which is suitable for anisotropic wet etching, in order to reduce etching time, to reduce hillocks on the etched surface (to reduce roughness), and to create a 45-degree wall angle (micro-mirror). This study would start by designing a wet etching system. There are four main components in this system: an ultrasonic cleaning, a condenser, a motor and a substrate holder. After that, an ultrasonic machine was modified by applying a condenser to maintain the consistency of the solution concentration during the etching process and installing a motor for improving the roughness. This effect on the etch rate and the roughness showed that the etch rate increased and the roughness was reduced.

Keywords: anisotropic wet etching, wet etching system, hillocks, ultrasonic cleaning

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Authors: Alina Zafar

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In this particular research, various morphometric characters such as total length (TL), wet weight (WW), standard length (SL), fork length (FL), head length (HL), head width (HW), body depth (BD), body girth (BG), dorsal fin length (DFL), pelvic fin length (PelFL), pectoral fin length (PecFL), anal fin length (AFL), dorsal fin base (DFB), anal fin base (AFB), caudal fin length (CFL) and caudal fin width (CFW) of wild collected Puntius sophore were studied, to know the types of growth patterns and correlations in reference to length and weight, however, high significant relationships were recorded between total length and wet weight, as the correlation coefficient (r) possessed value of 0.989. The growth pattern was observed to be positively allometric as the value of ‘b’ was 3.22 (slightly higher than the ideal value, 3) with 95% confidence intervals ranging from 3.076 to 3.372. Wet weight and total length parameters showed high significant correlations (p < 0.001) with all other morphometric characters.

Keywords: Puntius sophore, length and weight relation, morphometrics, small indigenous species

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Authors: Fares Senouci, Bachir Imine

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This document provides numerical and experimental optimization of the aerodynamic performance of a drone equipped with three types of horizontal stabilizer. To build this optimal configuration, an experimental and numerical study was conducted on three parameters: the geometry of the stabilizer (horizontal form or reverse V form), the position of the horizontal stabilizer (up or down), and the landing gear position (closed or open). The results show that up-stabilizer position with respect to the horizontal plane of the fuselage provides better aerodynamic performance, and that the landing gear increases the lift in the zone of stability, that is to say where the flow is not separated.

Keywords: aerodynamics, drag, lift, turbulence model, wind tunnel

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Authors: Busra Balli, Tuncay Dikici, Mustafa Toparli

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Titanium and its alloys have been used extensively over the past 25 years as biomedical materials in orthopedic and dental applications because of their good mechanical properties, corrosion resistance, and biocompatibility. It is known that the surface properties of titanium implants can enhance the cellular response and play an important role in Osseo integration. The rate and quality of Osseo integration in titanium implants are related to their surface properties. The purpose of this investigation was to evaluate the effect of sandblasting and acid etching on surface morphology, roughness, the wettability of titanium. The surface properties will be characterized by scanning electron microscopy and contact angle and roughness measurements. The results show that surface morphology, roughness, and wettability were changed and enhanced by these treatments.

Keywords: dental implant, etching, surface modifications, surface morphology, surface roughness

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Authors: Jean Marriz M. Manzano, Marc D. Rosales, Magdaleno R. Vasquez Jr., Maria Theresa G. De Leon

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This paper discusses the effects of surface roughness on a cantilever beam vibrational energy harvester. A silicon sample was fabricated using MEMS fabrication processes. When etching silicon using deep reactive ion etching (DRIE) at large etch depths, rougher surfaces are observed as a result of increased response in process pressure, amount of coil power and increased helium backside cooling readings. To account for the effects of surface roughness on the characteristics of the cantilever beam, finite element method (FEM) modeling was performed using actual roughness data from fabricated samples. It was found that when etching about 550um of silicon, root mean square roughness parameter, Sq, varies by 1 to 3 um (at 100um thick) across a 6-inch wafer. Given this Sq variation, FEM simulations predict an 8 to148 Hz shift in the resonant frequency while having no significant effect on the output power. The significant shift in the resonant frequency implies that careful consideration of surface roughness from fabrication processes must be done when designing energy harvesters.

Keywords: deep reactive ion etching, finite element method, microelectromechanical systems, multiphysics analysis, surface roughness, vibrational energy harvester

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Authors: Mohieddine Benghersallah, Mohamed Zakaria Zahaf, Ali Medjber, Idriss Tibakh

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The objective of this study is to analyse the effects of cutting parameters on surface roughness in dry face milling using statistical techniques. We studied the effect of the microstructure of AISI 52100 steel on machinability before and after hardening. The machining tests were carried out on a high rigidity vertical milling machine with a 25 mm diameter face milling cutter equipped with micro-grain bicarbide inserts with PVD (Ti, AlN) coating in GC1030 grade. A Taguchi L9 experiment plan is adopted. Analysis of variance (ANOVA) was used to determine the effects of cutting parameters (Vc, fz, ap) on the roughness (Ra) of the machined surface. Regression analysis to assess the machinability of steel presented mathematical models of roughness and the combination of parameters to minimize it. The recorded results show that feed per tooth has the most significant effect on the surface condition for both steel treatment conditions. The best roughnesses were obtained for the hardened AISI 52100 steel.

Keywords: machinability, heat treatment, microstructure, surface roughness, Taguchi method

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Authors: P. R. Prabhu, S. M. Kulkarni, S. S. Sharma, K. Jagannath, Achutha Kini U.

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In the present study, response surface methodology has been used to optimize turn-assisted deep cold rolling process of AISI 4140 steel. A regression model is developed to predict surface hardness and surface roughness using response surface methodology and central composite design. In the development of predictive model, deep cold rolling force, ball diameter, initial roughness of the workpiece, and number of tool passes are considered as model variables. The rolling force and the ball diameter are the significant factors on the surface hardness and ball diameter and numbers of tool passes are found to be significant for surface roughness. The predicted surface hardness and surface roughness values and the subsequent verification experiments under the optimal operating conditions confirmed the validity of the predicted model. The absolute average error between the experimental and predicted values at the optimal combination of parameter settings for surface hardness and surface roughness is calculated as 0.16% and 1.58% respectively. Using the optimal processing parameters, the hardness is improved from 225 to 306 HV, which resulted in an increase in the near surface hardness by about 36% and the surface roughness is improved from 4.84µm to 0.252 µm, which resulted in decrease in the surface roughness by about 95%. The depth of compression is found to be more than 300µm from the microstructure analysis and this is in correlation with the results obtained from the microhardness measurements. Taylor Hobson Talysurf tester, micro Vickers hardness tester, optical microscopy and X-ray diffractometer are used to characterize the modified surface layer.

Keywords: hardness, response surface methodology, microstructure, central composite design, deep cold rolling, surface roughness

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Authors: Marine Segui, Matthieu Mantilla, Ruxandra Mihaela Botez

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This research is the part of a major project at the Research Laboratory in Active Controls, Avionics and Aeroservoelasticity (LARCASE) aiming to improve a Cessna Citation X aircraft cruise performance with an application of the morphing wing technology on its horizontal tail. However, the horizontal stabilizer of the Cessna Citation X turns around its span axis with an angle between -8 and 2 degrees. Within this range, the horizontal stabilizer generates certainly some unwanted drag. To cancel this drag, the LARCASE proposes to trim the aircraft with a horizontal stabilizer equipped by a morphing wing technology. This technology aims to optimize aerodynamic performances by changing the conventional horizontal tail shape during the flight. As a consequence, this technology will be able to generate enough lift on the horizontal tail to balance the aircraft without an unwanted drag generation. To conduct this project, an accurate aerodynamic model of the horizontal tail is firstly required. This aerodynamic model will finally allow precise comparison between a conventional horizontal tail and a morphed horizontal tail results. This paper presents how this aerodynamic model was designed. In this way, it shows how the 2D geometry of the horizontal tail was collected and how the unknown airfoil’s shape of the horizontal tail has been recovered. Finally, the complete horizontal tail airfoil shape was found and a comparison between aerodynamic polar of the real horizontal tail and the horizontal tail found in this paper shows a maximum difference of 0.04 on the lift or the drag coefficient which is very good. Aerodynamic polar data of the aircraft horizontal tail are obtained from the CAE Inc. level D research aircraft flight simulator of the Cessna Citation X.

Keywords: aerodynamic, Cessna, citation, coefficient, Datcom, drag, lift, longitudinal, model, OpenVSP

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Authors: Sowntharya L.

Abstract:

Aerodynamics is the most important factor when it comes to resistive forces such as lift, drag and side forces acting on the vehicle. In passenger vehicles, reducing the drag will not only unlock the door for higher achievable speed but will also reduce the fuel consumption of the vehicle. Generally, tyre contributes significantly to the overall aerodynamics of the vehicle. Hence, understanding the air-flow behaviour around the tyre is vital to optimize the aerodynamic performance in the early stage of design process. Nowadays, aerodynamic simulation employing Computational Fluid Dynamics (CFD) is gaining more importance as it reduces the number of physical wind-tunnel experiments during vehicle development process. This research develops a methodology to predict aerodynamic drag of a standalone tyre using Numerical CFD Solver and to validate the same using a wind tunnel experiment. A parametric study was carried out on different tread pattern tyres such as slick, circumferential groove & patterned tyre in stationary and rotating boundary conditions. In order to represent wheel rotation contact with the ground, moving reference frame (MRF) approach was used in this study. Aerodynamic parameters such as drag lift & air flow behaviour around the tire were simulated and compared with experimental results.

Keywords: aerodynamics, CFD, drag, MRF, wind-tunnel

Procedia PDF Downloads 165

Authors: Harish Kumar Ponnappan, Joseph C. Chen

Abstract:

The main objective of this research is to optimize the surface roughness of a milling operation on AISI 1018 steel using live tooling on a HAAS ST-20 lathe. In this study, Taguchi analysis is used to optimize the milling process by investigating the effect of different machining parameters on surface roughness. The L₉ orthogonal array is designed with four controllable factors with three different levels each and an uncontrollable factor, resulting in 18 experimental runs. The optimal parameters determined from Taguchi analysis were feed rate – 76.2 mm/min, spindle speed 1150 rpm, depth of cut – 0.762 mm and 2-flute TiN coated high-speed steel as tool material. The process capability Cp and process capability index Cpk values were improved from 0.62 and -0.44 to 1.39 and 1.24 respectively. The average surface roughness values from the confirmation runs were 1.30 µ, decreasing the defect rate from 87.72% to 0.01%. The purpose of this study is to efficiently utilize the Taguchi design to optimize the surface roughness in a milling operation using live tooling.

Keywords: live tooling, surface roughness, taguchi analysis, CNC milling operation, CNC turning operation

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Authors: Yung C. Lin, Kung D. Wu, Wei C. Shih, Jui P. Hung

Abstract:

High speed and high precision machining have become the most important technology in manufacturing industry. The surface roughness of high precision components is regarded as the important characteristics of the product quality. However, machining chatter could damage the machined surface and restricts the process efficiency. Therefore, selection of the appropriate cutting conditions is of importance to prevent the occurrence of chatter. In addition, vibration of the spindle tool also affects the surface quality, which implies the surface precision can be controlled by monitoring the vibration of the spindle tool. Based on this concept, this study was aimed to investigate the influence of the machining conditions on the surface roughness and the vibration of the spindle tool. To this end, a series of machining tests were conducted on aluminum alloy. In tests, the vibration of the spindle tool was measured by using the acceleration sensors. The surface roughness of the machined parts was examined using white light interferometer. The response surface methodology (RSM) was employed to establish the mathematical models for predicting surface finish and tool vibration, respectively. The correlation between the surface roughness and spindle tool vibration was also analyzed by ANOVA analysis. According to the machining tests, machined surface with or without chattering was marked on the lobes diagram as the verification of the machining conditions. Using multivariable regression analysis, the mathematical models for predicting the surface roughness and tool vibrations were developed based on the machining parameters, cutting depth (a), feed rate (f) and spindle speed (s). The predicted roughness is shown to agree well with the measured roughness, an average percentage of errors of 10%. The average percentage of errors of the tool vibrations between the measurements and the predictions of mathematical model is about 7.39%. In addition, the tool vibration under various machining conditions has been found to have a positive influence on the surface roughness (r=0.78). As a conclusion from current results, the mathematical models were successfully developed for the predictions of the surface roughness and vibration level of the spindle tool under different cutting condition, which can help to select appropriate cutting parameters and to monitor the machining conditions to achieve high surface quality in milling operation.

Keywords: machining parameters, machining stability, regression analysis, surface roughness

Procedia PDF Downloads 203

Authors: Marzieh Khezerloo, Lyazid Djenidi

Abstract:

Owing to wide range of the micro-device applications, the problems of mixing at small scales is of significant interest. Also, because most of the processes produce heat, it is needed to develop and implement strategies for heat removal in these devices. There are many studies which focus on the effect of roughness or suction on heat transfer performance, separately, although it would be useful to take advantage of these two methods to improve heat transfer performance. Unfortunately, there is a gap in this area. The present numerical study is carried to investigate the combined effects of roughness and wall suction on heat transfer performance of a laminar channel flow; suction is applied on the top and back faces of the roughness element, respectively. The study is carried out for different Reynolds numbers, different suction rates, and various locations of suction area on the roughness. The flow is assumed two dimensional, incompressible, laminar, and steady state. The governing Navier-Stokes equations are solved using ANSYS-Fluent 18.2 software. The present results are tested against previous theoretical results. The results show that by adding suction, the local Nusselt number is enhanced in the channel. In addition, it is shown that by applying suction on the bottom section of the roughness back face, one can reduce the thickness of thermal boundary layer, which leads to an increase in local Nusselt number. This indicates that suction is an effective means for improving the heat transfer rate (suction by controls the thickness of thermal boundary layer). It is also shown that the size and intensity of vortical motion behind the roughness element, decreased with an increasing suction rate, which leads to higher local Nusselt number. So, it can be concluded that by using suction, strategically located on the roughness element, one can control both the recirculation region and the heat transfer rate. Further results will be presented at the conference for coefficient of drag and the effect of adding more roughness elements.

Keywords: heat transfer, laminar flow, numerical simulation, roughness, suction

Procedia PDF Downloads 92