Search results for: wall roughness

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: Eun Kyung Kim, Kyehan Rhee

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Viscoelastic wall properties of the arterial plaques change as the disease progresses, and estimation of wall viscoelasticity can provide a valuable assessment tool for plaque rupture prediction. Cross section of the stenotic coronary artery was modeled based on the IVUS image, and the finite element analysis was performed to get wall deformation under pulsatile pressure. The effects of viscoelastic parameters of the plaque on luminal diameter variations were explored. The result showed that decrease of viscous effect reduced the phase angle between the pressure and displacement waveforms, and phase angle was dependent on the viscoelastic properties of the wall. Because viscous effect of tissue components could be identified using the phase angle difference, wall deformation waveform analysis may be applied to predict plaque wall composition change and vascular wall disease progression.

Keywords: atherosclerotic plaque, diameter variation, finite element method, viscoelasticity

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Authors: Ahmed Rouili

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Cantilever L-shaped walls are known to be relatively economical as retaining solution. The design starts by proportioning the wall dimensions for which the stability is checked for. A ratio between the lengths of the base and the stem, falling between 0,5 to 0,7, ensure the stability requirements in most cases. However, the displacement pattern of the wall in terms of rotations and translations, and the lateral pressure profile, do not have the same figure for all wall’s proportioning, as it is usually assumed. In the present work, the results of a numerical analysis are presented, different wall geometries were considered. The results show that the proportioning governs the equilibrium between the instantaneous rotation and the translation of the wall-toe, also, the lateral pressure estimation based on the average value between the at-rest and the active pressure, recommended by most design standards, is found to be not applicable for all walls.

Keywords: cantilever wall, proportioning, numerical analysis, lateral pressure estimation

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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: Soo-yeon Seo, Su-jin Jung

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In recent years, the need for remodeling of many apartments built 30 years ago is increasing. Therefore, researches on the structural reinforcement technology of existing apartments have been conducted. On the other hand, there is a growing need for research on the existing underground space expansion technology to expand the parking space required for remodeling. When expanding an existing underground space, for earthworks, an earth retaining wall must be installed between the existing apartment building and it. In order to maximize the possible underground space, it is necessary to minimize the thickness of the portion of earth retaining wall and underground basement wall. In this manner, the calculation procedure is studied for the evaluation of shear strength of the composite basement wall corresponding to shear span-to-depth ratio in this study. As a result, it was shown that the proposed calculation procedure can be used to evaluate the shear strength of the composite basement wall as safe. On the other hand, when shear span-to-depth ratio is small, shear strength is very underestimated.

Keywords: underground space expansion, combined structure, temporary retaining wall, basement wall, shear connectors

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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: Harish Kumar Ponnappan, Joseph C. Chen

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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

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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

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Authors: Dhahri Maher, Aouinet Hana

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The presence of bubbles in the boundary layer introduces corrections into the log law, which must be taken into account. In this work, a logarithmic wall law was presented for bubbly two phase flows. The wall law presented in this work was based on the postulation of additional turbulent viscosity associated with bubble wakes in the boundary layer. The presented wall law contained empirical constant accounting both for shear induced turbulence interaction and for non-linearity of bubble. This constant was deduced from experimental data. The wall friction prediction achieved with the wall law was compared to the experimental data, in the case of a turbulent boundary layer developing on a vertical flat plate in the presence of millimetric bubbles. A very good agreement between experimental and numerical wall friction prediction was verified. The agreement was especially noticeable for the low void fraction when bubble induced turbulence plays a significant role.

Keywords: bubbly flows, log law, boundary layer, CFD

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Authors: B. Daee, H. M. El Naggar

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This paper presents an experimental study on structural performance of an innovative noise barrier consisting of poly-block, light polyurethane foam (LPF) and polyurea. This wall system (flexi-wall) is intended to be employed as a vertical extension to existing sound barriers in an accelerated construction method. To aid in the wall design, several mechanical tests were conducted on LPF specimens and two full-scale walls were then fabricated employing the same LPF material. The full-scale walls were subjected to lateral loading in order to establish their lateral resistance. A cyclic fatigue test was also performed on a full-scale flexi-wall in order to evaluate the performance of the wall under a repetitive loading condition. The result of the experiments indicated the suitability of flexi-wall in accelerated construction and confirmed that the structural performance of the wall system under lateral loading is satisfactory for the sound barrier application. The experimental results were discussed and a preliminary design procedure for application of flexi-wall in sound barrier applications was also developed.

Keywords: noise barrier, polyurethane foam, accelerated construction, full-scale experiment

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Authors: Suryapeta Harini

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Road surface roughness is one of the essential aspects of the road's functional condition, indicating riding comfort in both the transverse and longitudinal directions. The government of India has made maintaining good surface evenness a prerequisite for all highway projects. Pavement distress data was collected with a Network Survey Vehicle (NSV) on a National Highway. It determines the smoothness and frictional qualities of the pavement surface, which are related to driving safety and ease. Based on the data obtained in the field, a regression equation was created with the IRI value and the visual distresses. The suggested system can use wireless acceleration sensors and GPS to gather vehicle status and location data, as well as calculate the international roughness index (IRI). Potholes, raveling, rut depth, cracked area, and repair work are all affected by pavement roughness, according to the current study. The study was carried out in one location. Data collected through using Bump integrator was used for the validation. The bump integrator (BI) obtained using deflection from the network survey vehicle was correlated with the distress parameter to establish an equation.

Keywords: roughness index, network survey vehicle, regression, correlation

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Authors: Ouahiba Taamallah, Tarek Litim

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This work relates to the physico-geometrical aspect of the surface layers of 100C6 steel having undergone the burnishing treatment by hard steel ball. The application of tip diamond burnishing promotes better roughness compared to turning. In addition, it allows the surface layers to be consolidated by work hardening phenomena. The optimal effects are closely related to the parameters of the treatment and the active part of the device. With an 80% improvement in roughness resulting from the treatment, burnishing can be defined as a finishing operation within the machining range. With a 40% gain in consolidation rate, this treatment is an efficient process for material consolidation.

Keywords: 100C6 steel, burnishing, hardening, roughness

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Authors: Siamak Ghorbani, Nikolay Ivanovich Polushin

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Chatter vibrations, occurring during cutting process, cause vibration between the cutting tool and workpiece, which deteriorates surface roughness and reduces tool life. The purpose of this study is to investigate the influence of cutting parameters and tool construction on surface roughness and vibration in turning of aluminum alloy AA2024. A new design of cutting tool is proposed, which is filled up with epoxy granite in order to improve damping capacity of the tool. Experiments were performed at the lathe using carbide cutting insert coated with TiC and two different cutting tools made of AISI 5140 steel. Taguchi L9 orthogonal array was applied to design of experiment and to optimize cutting conditions. By the help of signal-to-noise ratio and analysis of variance the optimal cutting condition and the effect of the cutting parameters on surface roughness and vibration were determined. Effectiveness of Taguchi method was verified by confirmation test. It was revealed that new cutting tool with epoxy granite has reduced vibration and surface roughness due to high damping properties of epoxy granite in toolholder.

Keywords: ANOVA, damping capacity, surface roughness, Taguchi method, vibration

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Authors: L. Vafaei, McDominic Eze

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The performance of thermal energy in homes and buildings is a significant factor in terms of energy efficiency of a building. In a large sense, the performance of thermal energy is dependent on many factors of which the amount of thermal insulation is at one end a considerable factor, as likewise the essence of mass and the wall thickness and also the thermal resistance of wall material. This study is aimed at illustrating the different wall system in Turkish Republic of North Cyprus (TRNC), acknowledge the problem and suggest a solution through comparing the effect of thermal radiation two model rooms- L1 (Ytong wall) and L2 (heat insulated wall using stone wool) set up for experimentation. The model room has four face walls. The study consists of two stage, the first test is to access the effect of solar radiation for south facing wall and the second stage is to test the thermal performance of Ytong and heat insulated wall, the effects of climatic condition during winter. The heat insulated wall contains material hollow brick, stone wool, and gypsum while the Ytong wall contains cement concrete, for the outer surface and the inner surface and Ytong stone. The total heat of the wall was determined, 7T-Type thermocouple was used with a data logger system to record the data, temperature change recorded at an interval of 10 minutes. The result obtained was that Ytong wall save more energy than the heat insulated wall at night while heat insulated wall saves energy during the day when intensity is at maximum.

Keywords: heat insulation, hollow bricks, south facing, Ytong bricks wall

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Authors: Abdallah M. Abdelkawy, Tarek M. El Hossainya, I. El Mahallawib

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Recently, significant achievements have been made in development and manufacturing of nano-dispersed metal matrix nanocomposites (MMNCs). They gain their importance due to their high strength to weight ratio. The machining problems of these new materials are less widely investigated, thus this work focuses on machining of them. Aluminum-Silicon (A356)/ MMNC dispersed with alumina (Al2O3) is important in many applications include engine blocks. The final finish process of this application depends heavily on machining. The most important machining parameter studied includes: cutting force and surface roughness. Experimental trails are performed on the number of special samples of MMNC (with different Al2O3%) where the relation between Al2O3% and cutting speed, feed rate and cutting depth with cutting force and surface roughness were studied. The data obtained were statistically analyzed using Analysis of variance (ANOVA) to define the significant factors on both cutting force and surface roughness and their level of confident. Response Surface Methodology (RSM) is used to build a model relating cutting conditions and Al2O3% to the cutting force and surface roughness. The results have shown that feed and depth of cut have the major contribution on the cutting force and the surface roughness followed by cutting speed and nano-percent in MMNCs.

Keywords: machinability, cutting force, surface roughness, Ra, RSM, ANOVA, MMNCs

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Authors: Joseph C. Chen, Joshua Cox

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This research focuses on the use of the Taguchi method to reduce the surface roughness and improve dimensional accuracy of parts machined by Wire Electrical Discharge Machining (EDM) with S7 heat treated steel material. Due to its high impact toughness, the material is a candidate for a wide variety of tooling applications which require high precision in dimension and desired surface roughness. This paper demonstrates that Taguchi Parameter Design methodology is able to optimize both dimensioning and surface roughness successfully by investigating seven wire-EDM controllable parameters: pulse on time (ON), pulse off time (OFF), servo voltage (SV), voltage (V), servo feed (SF), wire tension (WT), and wire speed (WS). The temperature of the water in the Wire EDM process is investigated as the noise factor in this research. Experimental design and analysis based on L₁₈ Taguchi orthogonal arrays are conducted. This paper demonstrates that the Taguchi-based system enables the wire EDM process to produce (1) high precision parts with an average of 0.6601 inches dimension, while the desired dimension is 0.6600 inches; and (2) surface roughness of 1.7322 microns which is significantly improved from 2.8160 microns.

Keywords: Taguchi Parameter Design, surface roughness, Wire EDM, dimensional accuracy

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Authors: Alireza Mirzaee, Soosan Abdollahi, Mohammad Abdollahi

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Unreinforced Masonry (URM) wall is vulnerable in resisting horizontal load such as wind and seismic loading. It is due to the low tensile strength of masonry, the mortar connection between the brick units. URM structures are still widely used in the world as an infill wall and commonly constructed with door and window openings. This research aimed to investigate the behavior of URM wall with openings when horizontal load acting on it and developed load-drift relationship of the wall. The finite element (FE) method was chosen to numerically simulate the behavior of URM with openings. In this research, ABAQUS, commercially available FE software with explicit solver was employed. In order to ensure the numerical model can accurately represent the behavior of an URM wall, the model was validated for URM wall without openings using available experimental results. Load-displacement relationship of numerical model is well agreed with experimental results. Evidence shows the same load displacement curve shape obtained from the FE model. After validating the model, parametric study conducted on URM wall with openings to investigate the influence of area of openings and pre-compressive load on the horizontal load capacity of the wall. The result showed that the increasing of area of openings decreases the capacity of the wall in resisting horizontal loading. It is also well observed from the result that capacity of the wall increased with the increasing of pre-compressive load applied on the top of the walls.

Keywords: masonry constructions, performance at earthquake, MSJC-08 (ASD), bearing wall, tie-column

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Authors: Mehmet Erdi Korkmaz, Mustafa Günay

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Nowadays, grinding is frequently replaced with hard turning for reducing set up time and higher accuracy. This paper focused on mathematical modeling of average surface roughness (Ra) in hard turning of AISI L2 grade (DIN 1.2210) cold work tool steel with ceramic tools. The steel was hardened to 60±1 HRC after the heat treatment process. Cutting speed, feed rate, depth of cut and tool nose radius was chosen as the cutting conditions. The uncoated ceramic cutting tools were used in the machining experiments. The machining experiments were performed according to Taguchi L27 orthogonal array on CNC lathe. Ra values were calculated by averaging three roughness values obtained from three different points of machined surface. The influences of cutting conditions on surface roughness were evaluated as statistical and experimental. The analysis of variance (ANOVA) with 95% confidence level was applied for statistical analysis of experimental results. Finally, mathematical models were developed using the artificial neural networks (ANN). ANOVA results show that feed rate is the dominant factor affecting surface roughness, followed by tool nose radius and cutting speed.

Keywords: ANN, hard turning, DIN 1.2210, surface roughness, Taguchi method

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Authors: Sky Chou, Joseph C. Chen

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This paper focuses on using Six Sigma methodologies to improve the surface roughness of a manufactured part produced by the CNC milling machine. It presents a case study where the surface roughness of milled aluminum is required to reduce or eliminate defects and to improve the process capability index C_p and C_pk for a CNC milling process. The six sigma methodology, DMAIC (design, measure, analyze, improve, and control) approach, was applied in this study to improve the process, reduce defects, and ultimately reduce costs. The Taguchi-based six sigma approach was applied to identify the optimized processing parameters that led to the targeted surface roughness specified by our customer. A L₉ orthogonal array was applied in the Taguchi experimental design, with four controllable factors and one non-controllable/noise factor. The four controllable factors identified consist of feed rate, depth of cut, spindle speed, and surface roughness. The noise factor is the difference between the old cutting tool and the new cutting tool. The confirmation run with the optimal parameters confirmed that the new parameter settings are correct. The new settings also improved the process capability index. The purpose of this study is that the Taguchi–based six sigma approach can be efficiently used to phase out defects and improve the process capability index of the CNC milling process.

Keywords: CNC machining, six sigma, surface roughness, Taguchi methodology

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Authors: S. Atabay, T. A. Ali, Md. M. Mortula

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This paper presents the results and findings from a parametric study on the water surface elevation at upstream of bridge constriction for subcritical flow. In this study, the influence of Manning's Roughness Coefficient of main channel (nmc) and of floodplain (nfp), and bridge opening (b) flow rate (Q), contraction (kcon), and expansion coefficients (kexp) were investigated on backwater level. The DECK bridge models with different span widths and without any pier were investigated within the two stage channel having various roughness conditions. One of the most commonly used commercial one-dimensional HEC-RAS model was used in this parametric study. This study showed that the effects of main channel roughness (nmc) and flow rate (Q) on the backwater level are much higher than those of the floodplain roughness (nfp). Bridge opening (b) with contraction (kcon) and expansion coefficients (kexp) have very little effect on the backwater level within this range of parameters.

Keywords: bridge backwater, parametric study, waterways, HEC-RAS model

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Authors: Ahmed S. Abdulrasool

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Recently sand wall started to gain more attention as the sand is easy to compact by using vibroflotation technique. An advantage of sand wall is the availability of different additives that can be mixed with sand to increase the stiffness of the sand wall and hence to increase its performance. In this paper, the bearing capacity of circular foundation surrounded by sand wall stabilized with lime is evaluated through laboratory testing. The studied parameters include different sand-lime walls depth (H/D) ratio (wall depth to foundation diameter) ranged between (0.0-3.0). Effect of lime percentages on the bearing capacity of skirted foundation models is investigated too. From the results, significant change is occurred in the behavior of shallow foundations due to confinement of the soil. It has been found that (H/D) ratio of 2 gives substantial improvement in bearing capacity, and beyond (H/D) ratio of 2, there is no significant improvement in bearing capacity. The results show that the optimum lime content is 11%, and the maximum increase in bearing capacity reaches approximately 52% at (H/D) ratio of 2.

Keywords: bearing capacity, circular foundation, clay soil, lime-sand wall

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Authors: Ajay Kumar Sarathe, Abhinay Kumar

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Production of quality products required for specific engineering applications is an important issue. The roughness of the surface plays an important role in the quality of the product by using appropriate machining parameters to eliminate wastage due to over machining. To increase the quality of the surface, the optimum machining parameter setting is crucial during the machining operation. The effect of key machining parameters- spindle speed, feed rate, and depth of cut on surface roughness has been evaluated. Experimental work was carried out using High Speed Steel tool and AlSI 1018 as workpiece material. In this study, the predictive model has been developed using Box-Behnken Design. An experimental investigation has been carried out for this work using BBD for three factors and observed that the predictive model of Ra value is closed to predictive value with a marginal error of 2.8648 %. Developed model establishes a correlation between selected key machining parameters that influence the surface roughness in a AISI 1018. F

Keywords: ANOVA, BBD, optimisation, response surface methodology

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Authors: S. Gao, S. Srirattayawong

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In this study, a computational fluid dynamics (CFD) model has been developed for studying the effect of surface roughness profile on the EHL problem. The cylinders contact geometry, meshing and calculation of the conservation of mass and momentum equations are carried out by using the commercial software packages ICEMCFD and ANSYS Fluent. The user defined functions (UDFs) for density, viscosity and elastic deformation of the cylinders as the functions of pressure and temperature have been defined for the CFD model. Three different surface roughness profiles are created and incorporated into the CFD model. It is found that the developed CFD model can predict the characteristics of fluid flow and heat transfer in the EHL problem, including the leading parameters such as the pressure distribution, minimal film thickness, viscosity, and density changes. The obtained results show that the pressure profile at the center of the contact area directly relates to the roughness amplitude. The rough surface with kurtosis value over 3 influences the fluctuated shape of pressure distribution higher than other cases.

Keywords: CFD, EHL, kurtosis, surface roughness

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Authors: Louis Denis Kevin Catherine, Raja Aziz Raja Ma’arof, Azrina Arshad, Sangeeth Suresh

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Machining parameters are very important in determining the surface quality of any material. In the past decade, some new engineering materials were developed for the manufacturing industry which created a need to conduct an investigation on the impact of the said parameters on their surface roughness. The polyurethane (PU) block is widely used in the automotive industry to manufacture parts such as checking fixtures that are used to verify the dimensional accuracy of automotive parts. In this paper, the design of experiment (DOE) was used to investigate the effect of the milling parameters on the PU block. Furthermore, an analysis of the machined surface chemical composition was done using scanning electron microscope (SEM). It was found that the surface roughness of the PU block is severely affected when PU undergoes a flood machining process instead of a dry condition. In addition, the step over and the silicon content were found to be the most significant parameters that influence the surface quality of the PU block.

Keywords: polyurethane (PU), design of experiment (DOE), scanning electron microscope (SEM), surface roughness

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Authors: H. Nikzad, S. Yoshitomi

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In this paper, an optimization procedure is applied for 3D Reinforced concrete building structure with shear wall.  In the optimization problem, cross sections of beams, columns and shear wall dimensions are considered as design variables and the optimal cross sections can be derived to minimize the total cost of the structure. As for final design application, the most suitable sections are selected to satisfy ACI 318-14 code provision based on static linear analysis. The validity of the method is examined through numerical example of 15 storied 3D RC building with shear wall.  This optimization method is expected to assist in providing a useful reference in design early stage, and to be an effective and powerful tool for structural design of RC shear wall structures.

Keywords: structural optimization, linear static analysis, ETABS, MATLAB, RC moment frame, RC shear wall structures

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Authors: Nurul Na'imy Wan, Mohamad Sazali Said, Jaharah Ab. Ghani, Rusli Othman

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This paper presents the surface roughness of the aluminium silicon alloy (AlSi) matrix composite which has been reinforced with aluminium nitride (AlN). Experiments were conducted at various cutting speeds, feed rates, and depths of cut, according to a standard orthogonal array L27 of Taguchi method using TiN coating tool of insert. The signal-to-noise (S/N) ratio and analysis of variance are applied to study the characteristic performance of cutting speeds, feed rates and depths of cut in measuring the surface roughness during the milling operation. The surface roughness was observed using Mitutoyo Formtracer CS-500 and analyzed using the Taguchi method. From the Taguchi analysis, it was found that cutting speed of 230 m/min, feed rate of 0.4 mm/tooth, depth of cut of 0.3 mm were the optimum machining parameters using TiN coating insert.

Keywords: AlSi/AlN metal matrix composite (MMC), surface roughness, Taguchi method, machining parameters

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Authors: Roman Medvedev, Andrey Yakshin, Konstantin Nikolaev, Sergey Yakunin, Fred Bijkerk

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Multilayer structures are used as spectroscopic elements in fluorescence analysis. These serve the purpose of analyzing soft x-ray emission spectra of materials upon excitation by x-rays or electrons. The analysis then allows quantitative determination of the x-ray emitting elements in the materials. Shorter wavelength range for this application, below 2.5nm, can be covered by using short period multilayers, with a period of 2.5 nm and lower. Thus the detrimental effect on the reflectivity of morphological roughness between materials of the multilayers becomes increasingly pronounced. Ion beam polishing was previously shown to be effective in reducing roughness in some multilayer systems with Si. In this work, we explored W/Si multilayers with the period of 2.5 nm. Si layers were polishing by Ar ions, employing low energy ions, 100 and 80 eV, with the etched Si thickness being in the range 0.1 to 0.5 nm. CuK X-ray diffuse scattering measurements revealed a significant reduction in the diffused scattering in the polished multilayers. However, Grazing Incidence CuK X-ray showed only a marginal reduction of the overall roughness of the systems. Still, measurements of the structures with Grazing Incidence Small Angle X-ray scattering indicated that the vertical correlation length of roughness was strongly reduced in the polished multilayers. These results together suggest that polishing results in the reduction of the vertical propagation of roughness from layer to layer, while only slightly affecting the overall roughness. This phenomenon can be explained by ion-induced surface roughening inherently present in the ion polishing methods. Alternatively, ion-induced densification of thin Si films should also be considered. Finally, the reflectivity of 40% at 0.84 nm at grazing incidence of 9 degrees has been obtained in this work for W/Si multilayers. Analysis of the obtained results is expected to lead to further progress in reflectance.

Keywords: interface roughness, ion polishing, multilayer structures, W/Si

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Authors: Khizir Mohd Ismail, Yu Jun Lim, Tshun Howe Yong

Abstract:

The study of flow behavior in an enclosed volume using Computational Fluid Dynamics (CFD) has been around for decades. However, due to the knowledge limitation of adaptive grid methods, the flow in an enclosed volume near the moving wall using CFD is less explored. A CFD simulation of flow in an enclosed volume near a moving wall was demonstrated and studied by introducing a moving mesh method and was modeled with Unsteady Reynolds-Averaged Navier-Stokes (URANS) approach. A static enclosed volume with controlled opening size in the bottom was positioned against a moving, translational wall with sliding mesh features. Controlled variables such as smoothed, crevices and corrugated wall characteristics, the distance between the enclosed volume to the wall and the moving wall speed against the enclosed chamber were varied to understand how the flow behaves and reacts in between these two geometries. These model simulations were validated against experimental results and provided result confidence when the simulation had shown good agreement with the experimental data. This study had provided better insight into the flow behaving in an enclosed volume when various wall types in motion were introduced within the various distance between each other and create a potential opportunity of application which involves adaptive grid methods in CFD.

Keywords: moving wall, adaptive grid methods, CFD, moving mesh method

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