Search results for: longitudinal roughness

Authors: Sky Chou, Joseph C. Chen

Abstract:

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: Md Abdullah Al Faruque, Ram Balachandar

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Sudden change of bed condition is frequent in open channel flow. Change of bed condition affects the turbulence characteristics in both streamwise and wall-normal direction. Understanding the turbulence intensity in open channel flow is of vital importance to the modeling of sediment transport and resuspension, bed formation, entrainment, and the exchange of energy and momentum. A comprehensive study was carried out to understand the extent of the effect of Reynolds number and bed roughness on different turbulence characteristics in an open channel flow. Four different bed conditions (impervious smooth bed, impervious continuous rough bed, pervious rough sand bed, and impervious distributed roughness) and two different Reynolds numbers were adopted for this cause. The effect of bed roughness on different turbulence characteristics is seen to be prevalent for most of the flow depth. Effect of Reynolds number on different turbulence characteristics is also evident for flow over different bed, but the extent varies on bed condition. Although the same sand grain is used to create the different rough bed conditions, the difference in turbulence characteristics is an indication that specific geometry of the roughness has an influence on turbulence characteristics. Roughness increases the contribution of the extreme turbulent events which produces very large instantaneous Reynolds shear stress and can potentially influence the sediment transport, resuspension of pollutant from bed and alter the nutrient composition, which eventually affect the sustainability of benthic organisms.

Keywords: Open channel flow, Reynolds Number, roughness, turbulence.

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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 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 are 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 main parameters such as pressure distribution, minimal film thickness, viscosity, and density changes. The results obtained show that the pressure profile at the center of the contact area directly relates to the roughness amplitude. A rough surface with kurtosis value of more than 3 has greater influence over the fluctuated shape of pressure distribution than in other cases.

Keywords: CFD, EHL, Kurtosis, Surface roughness.

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Authors: Salah Gariani, Taher Dao, Khaled Jegandi

Abstract:

Wiper inserts are widely used nowadays, particularly in turning and milling operations, due to their unique geometric characteristics that generate superb surface finish and improve productivity. Wiper inserts can produce double the feed rate while preserving comparable surface roughness compared to that produced by conventional cutting tools. This paper reports an experimental investigation of surface quality generated in the precision dry turning of 6060 Aluminium alloy using conventional and wiper inserts at different cutting conditions. The Taguchi L9 array, Analysis of Means (AOM) and variance (ANOVA) were employed in the development of the experimental design and to optimise the process parameter identified: average surface roughness (Ra). The experimental results show that the wiper inserts substantially improved the surface quality of the machined samples by a factor of two compared to those for the conventional insert under all cutting conditions. The ANOVA and AOM analysis showed that the type of insert is the most significant factor affecting surface roughness, with a Percentage Contribution Ratio (PCR) value of 67.41%. Feed rate also significantly affected surface roughness but contributed less to its variation. No significant difference was found between values of Ra using wiper inserts under dry and wet cooling modes when turning 6060 Aluminium alloy.

Keywords: 6060 Aluminium alloy, conventional and wiper carbide tools, dry turning, average surface roughness.

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

Abstract:

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. 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 on 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 stepover 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: Sedigheh Mirzaei S., Debasis Sengupta

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Parametric models have been quite popular for studying human growth, particularly in relation to biological parameters such as peak size velocity and age at peak size velocity. Longitudinal data are generally considered to be vital for fittinga parametric model to individual-specific data, and for studying the distribution of these biological parameters in a human population. However, cross-sectional data are easier to obtain than longitudinal data. In this paper, we present a method of combining longitudinal and cross-sectional data for the purpose of estimating the distribution of the biological parameters. We demonstrate, through simulations in the special case ofthePreece Baines model, how estimates based on longitudinal data can be improved upon by harnessing the information contained in cross-sectional data.We study the extent of improvement for different mixes of the two types of data, and finally illustrate the use of the method through data collected by the Indian Statistical Institute.

Keywords: Preece-Baines growth model, MCMC method, Mixed effect model

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Authors: Sang-Yoon Lee, Jung-Mi Lee, Hyeong-Yeol Kim, Jae-Joon Song

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In this study, a longitudinal joint connection was proposed for the short-span slab-type modular bridges with rapid construction. The slab-type modular bridge consists of a number of precast slab modules and has the joint connection between the modules in the longitudinal direction of the bridge. A finite element based parameter analysis was conducted to design the shape and the dimensions of the longitudinal joint connection. Numbers of shear keys within the joint, height and depth of the shear key, tooth angle, and the spacing were considered as the design parameters. Using the local cracking load at the corner of the shear key and the cross-sectional area of the joint, an efficiency factor was proposed to evaluate the effectiveness of the longitudinal joint connection. The dimensions of shear key were determined by comparing the cracking loads and the efficiency factors obtained from the finite element analysis.

Keywords: precast, slab bridge, modular bridge, shear key

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Authors: S. M. Rifat, André L. Marchildon, Mark F. Tachie

Abstract:

Experiments were performed to investigate the effects of roughness on the reattachment and redevelopment regions over a 12 mm forward facing step (FFS) in an open channel flow. The experiments were performed over an upstream smooth wall and a smooth FFS, an upstream wall coated with sandpaper 36 grit and a smooth FFS and an upstream rough wall produced from sandpaper 36 grit and a FFS coated with sandpaper 36 grit. To investigate only the wall roughness effects, Reynolds number, Froude number, aspect ratio and blockage ratio were kept constant. Upstream profiles showed reduced streamwise mean velocities close to the rough wall compared to the smooth wall, but the turbulence level was increased by upstream wall roughness. The reattachment length for the smooth-smooth wall experiment was 1.78h; however, when it is replaced with rough-smooth wall the reattachment length decreased to 1.53h. It was observed that the upstream roughness increased the physical size of contours of maximum turbulence level; however, the downstream roughness decreased both the size and magnitude of contours in the vicinity of the leading edge of the step. Quadrant analysis was performed to investigate the dominant Reynolds shear stress contribution in the recirculation region. The Reynolds shear stress and turbulent kinetic energy profiles after the reattachment showed slower recovery compared to the streamwise mean velocity, however all the profiles fairly collapse on their corresponding upstream profiles at x/h = 60. It was concluded that to obtain a complete collapse several more streamwise distances would be required.

Keywords: Forward facing step, open channel, separated and reattached turbulent flows, wall roughness.

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Authors: Anjian Chen, Joseph C. Chen

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This paper studies a case where the targeted surface roughness of fused deposition modeling (FDM) additive manufacturing process is improved. The process is designing to reduce or eliminate the defects and improve the process capability index Cp and Cpk for an FDM additive manufacturing process. The baseline Cp is 0.274 and Cpk is 0.654. This research utilizes the Taguchi methodology, to eliminate defects and improve the process. The Taguchi method is used to optimize the additive manufacturing process and printing parameters that affect the targeted surface roughness of FDM additive manufacturing. The Taguchi L9 orthogonal array is used to organize the parameters' (four controllable parameters and one non-controllable parameter) effectiveness on the FDM additive manufacturing process. The four controllable parameters are nozzle temperature [°C], layer thickness [mm], nozzle speed [mm/s], and extruder speed [%]. The non-controllable parameter is the environmental temperature [°C]. After the optimization of the parameters, a confirmation print was printed to prove that the results can reduce the amount of defects and improve the process capability index Cp from 0.274 to 1.605 and the Cpk from 0.654 to 1.233 for the FDM additive manufacturing process. The final results confirmed that the Taguchi methodology is sufficient to improve the surface roughness of FDM additive manufacturing process.

Keywords: Additive manufacturing, fused deposition modeling, surface roughness, Six-Sigma, Taguchi method, 3D printing.

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Authors: Naushad Mamode Khan

Abstract:

The Com-Poisson (CMP) model is one of the most popular discrete generalized linear models (GLMS) that handles both equi-, over- and under-dispersed data. In longitudinal context, an integer-valued autoregressive (INAR(1)) process that incorporates covariate specification has been developed to model longitudinal CMP counts. However, the joint likelihood CMP function is difficult to specify and thus restricts the likelihood-based estimating methodology. The joint generalized quasi-likelihood approach (GQL-I) was instead considered but is rather computationally intensive and may not even estimate the regression effects due to a complex and frequently ill-conditioned covariance structure. This paper proposes a new GQL approach for estimating the regression parameters (GQL-III) that is based on a single score vector representation. The performance of GQL-III is compared with GQL-I and separate marginal GQLs (GQL-II) through some simulation experiments and is proved to yield equally efficient estimates as GQL-I and is far more computationally stable.

Keywords: Longitudinal, Com-Poisson, Ill-conditioned, INAR(1), GLMS, GQL.

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Authors: L. Bennaceur Farah, I. R. Farah, R. Bennaceur, Z. Belhadj, M. R. Boussema

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The overall objective of this paper is to retrieve soil surfaces parameters namely, roughness and soil moisture related to the dielectric constant by inverting the radar backscattered signal from natural soil surfaces. Because the classical description of roughness using statistical parameters like the correlation length doesn't lead to satisfactory results to predict radar backscattering, we used a multi-scale roughness description using the wavelet transform and the Mallat algorithm. In this description, the surface is considered as a superposition of a finite number of one-dimensional Gaussian processes each having a spatial scale. A second step in this study consisted in adapting a direct model simulating radar backscattering namely the small perturbation model to this multi-scale surface description. We investigated the impact of this description on radar backscattering through a sensitivity analysis of backscattering coefficient to the multi-scale roughness parameters. To perform the inversion of the small perturbation multi-scale scattering model (MLS SPM) we used a multi-layer neural network architecture trained by backpropagation learning rule. The inversion leads to satisfactory results with a relative uncertainty of 8%.

Keywords: Remote sensing, rough surfaces, inverse problems, SAR, radar scattering, Neural networks and Fractals.

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Authors: Anjan Kumar Kakati, M. Chandrasekaran, Amitava Mandal, Amit Kumar Singh

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End milling process is one of the common metal cutting operations used for machining parts in manufacturing industry. It is usually performed at the final stage in manufacturing a product and surface roughness of the produced job plays an important role. In general, the surface roughness affects wear resistance, ductility, tensile, fatigue strength, etc., for machined parts and cannot be neglected in design. In the present work an experimental investigation of end milling of aluminium alloy with carbide tool is carried out and the effect of different cutting parameters on the response are studied with three-dimensional surface plots. An artificial neural network (ANN) is used to establish the relationship between the surface roughness and the input cutting parameters (i.e., spindle speed, feed, and depth of cut). The Matlab ANN toolbox works on feed forward back propagation algorithm is used for modeling purpose. 3-12-1 network structure having minimum average prediction error found as best network architecture for predicting surface roughness value. The network predicts surface roughness for unseen data and found that the result/prediction is better. For desired surface finish of the component to be produced there are many different combination of cutting parameters are available. The optimum cutting parameter for obtaining desired surface finish, to maximize tool life is predicted. The methodology is demonstrated, number of problems are solved and algorithm is coded in Matlab®.

Keywords: End milling, Surface roughness, Neural networks.

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Authors: Wichai Pattanapol, Sarah J. Wakes, Michael J. Hilton, Katharine J.M. Dickinson

Abstract:

Turbulence modeling of large-scale flow over a vegetated surface is complex. Such problems involve large scale computational domains, while the characteristics of flow near the surface are also involved. In modeling large scale flow, surface roughness including vegetation is generally taken into account by mean of roughness parameters in the modified law of the wall. However, the turbulence structure within the canopy region cannot be captured with this method, another method which applies source/sink terms to model plant drag can be used. These models have been developed and tested intensively but with a simple surface geometry. This paper aims to compare the use of roughness parameter, and additional source/sink terms in modeling the effect of plant drag on wind flow over a complex vegetated surface. The RNG k-ε turbulence model with the non-equilibrium wall function was tested with both cases. In addition, the k-ω turbulence model, which is claimed to be computationally stable, was also investigated with the source/sink terms. All numerical results were compared to the experimental results obtained at the study site Mason Bay, Stewart Island, New Zealand. In the near-surface region, it is found that the results obtained by using the source/sink term are more accurate than those using roughness parameters. The k-ω turbulence model with source/sink term is more appropriate as it is more accurate and more computationally stable than the RNG k-ε turbulence model. At higher region, there is no significant difference amongst the results obtained from all simulations.

Keywords: CFD, canopy flow, surface roughness, turbulence models.

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Authors: J. Chen, N. Hundal

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Conventional machining is a form of subtractive manufacturing, in which a collection of material-working processes utilizing power-driven machine tools are used to remove undesired material to achieve a desired geometry. This paper presents an approach for comparison between turning center and vertical machining center by optimization of cutting parameters at cylindrical workpieces leading to minimum surface roughness by using taguchi methodology. Aluminum alloy was taken to conduct experiments due to its unique high strength-weight ratio that is maintained at elevated temperatures and their exceptional corrosion resistance. During testing, the effects of the cutting parameters on the surface roughness were investigated. Additionally, by using taguchi methodology for each of the cutting parameters (spindle speed, depth of cut, insert diameter, and feed rate) minimum surface roughness for the process of turn-milling was determined according to the cutting parameters. A confirmation experiment demonstrates the effectiveness of taguchi method.

Keywords: Surface roughness, taguchi parameter design, turning center, turn-milling operations, vertical machining center.

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Authors: F.Agalianos, S.Patelis , P. Kyratsis, E. Maravelakis, E.Vasarmidis, A.Antoniadis

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Laser engraving is a manufacturing method for those applications where previously Electrical Discharge Machining (EDM) was the only choice. Laser engraving technology removes material layer-by-layer and the thickness of layers is usually in the range of few microns. The aim of the present work is to investigate the influence of the process parameters on the surface quality when machined by laser engraving. The examined parameters were: the pulse frequency, the beam speed and the layer thickness. The surface quality was determined by the surface roughness for every set of parameters. Experimental results on Al7075 material showed that the surface roughness strictly depends on the process parameters used.

Keywords: Laser engraving, Al7075, Yb: YAG laser, laser process parameters, material roughness.

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Authors: Vladimir Aleksandrovich Rogov, Ghorbani Siamak

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Determination of optimal conditions of machining parameters is important to reduce the production cost and achieve the desired surface quality. This paper investigates the influence of cutting parameters on surface roughness and natural frequency in turning of aluminum alloy AA2024. The experiments were performed at the lathe machine using two different cutting tools made of AISI 5140 and carbide cutting insert coated with TiC. Turning experiments were planned by Taguchi method L₉ orthogonal array.Three levels for spindle speed, feed rate, depth of cut and tool overhang were chosen as cutting variables. The obtained experimental data has been analyzed using signal to noise ratio and analysis of variance. The main effects have been discussed and percentage contributions of various parameters affecting surface roughness and natural frequency, and optimal cutting conditions have been determined. Finally, optimization of the cutting parameters using Taguchi method was verified by confirmation experiments.

Keywords: Turning, Cutting conditions, Surface roughness, Natural frequency, Taguchi method, ANOVA, S/N ratio.

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Authors: Arash Mir Abdolah Lavasani, Hamidreza Bayat

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Heat transfer from two cam shape cylinder in tandem arrangement had been studied numerically. The distance between the centers of cylinders (L) is allowed to vary to change the longitudinal pitch ratio (L/Deq). The equivalent diameter of the cylinder (Deq) is 27.6 mm and longitudinal pitch ratio varies in range 2<L/Deq<6. The Reynolds number based on equivalent circular cylinder are within 50< Reeq <300. Results show that Nusselt number of second cylinder increases about 5 to 33 times when longitudinal pitch ratio increases from 2 to 6.

Keywords: Cam Shaped, tandem Cylinders, Numerical, Heat Transfer.

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Authors: Manop Vorasri, Komson Jirapattarasilp, Sittichai Kaewkuekool

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The objective of this research was to study factors, which were affected on surface roughness in high speed milling of hardened tool steel. Material used in the experiment was tool steel JIS SKD 61 that hardened on 60 ±2 HRC. Full factorial experimental design was conducted on 3 factors and 3 levels (3 3 designs) with 2 replications. Factors were consisted of cutting speed, feed rate, and depth of cut. The results showed that influenced factor affected to surface roughness was cutting speed, feed rate and depth of cut which showed statistical significant. Higher cutting speed would cause on better surface quality. On the other hand, higher feed rate would cause on poorer surface quality. Interaction of factor was found that cutting speed and depth of cut were significantly to surface quality. The interaction of high cutting speed associated with low depth of cut affected to better surface quality than low cutting speed and high depth of cut.

Keywords: High-speed milling, Tool steel, SKD 61 Steel, Surface roughness, Cutting speed, Feed rate, Depth of cut

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Authors: Nahla H. Alaswadko, Rayya A. Hassan, Bayar N. Mohammed

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Empirical deterministic models have been developed to predict roughness progression of heavy duty spray sealed pavements for a dataset representing rural arterial roads. The dataset provides a good representation of the relevant network and covers a wide range of operating and environmental conditions. A sample with a large size of historical time series data for many pavement sections has been collected and prepared for use in multilevel regression analysis. The modelling parameters include road roughness as performance parameter and traffic loading, time, initial pavement strength, reactivity level of subgrade soil, climate condition, and condition of drainage system as predictor parameters. The purpose of this paper is to report the approaches adopted for models development and validation. The study presents multilevel models that can account for the correlation among time series data of the same section and to capture the effect of unobserved variables. Study results show that the models fit the data very well. The contribution and significance of relevant influencing factors in predicting roughness progression are presented and explained. The paper concludes that the analysis approach used for developing the models confirmed their accuracy and reliability by well-fitting to the validation data.

Keywords: Roughness progression, empirical model, pavement performance, heavy duty pavement.

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Authors: Nassier A. Nassir, Robert Birch, D. Rico Sierra, S. P. Edwardson, G. Dearden, Zhongwei Guan

Abstract:

The effect of laser surface treatment parameters on the residual strength of titanium alloy has been investigated. The influence of the laser surface treatment on the bonding strength between the titanium and poly-ether-ketone-ketone (PEKK) surfaces was also evaluated and compared to those offered by titanium foils without surface treatment to optimize the laser parameters. Material characterization using an optical microscope was carried out to study the microstructure and to measure the mean roughness value of the titanium surface. The results showed that the surface roughness shows a significant dependency on the laser power parameters in which surface roughness increases with the laser power increment. Moreover, the results of the tensile tests have shown that there is no significant dropping in tensile strength for the treated samples comparing to the virgin ones. In order to optimize the laser parameter as well as the corresponding surface roughness, single-lap shear tests were conducted on pairs of the laser treated titanium stripes. The results showed that the bonding shear strength between titanium alloy and PEKK film increased with the surface roughness increment to a specific limit. After this point, it is interesting to note that there was no significant effect for the laser parameter on the bonding strength. This evidence suggests that it is not necessary to use very high power of laser to treat titanium surface to achieve a good bonding strength between titanium alloy and the PEKK film.

Keywords: Bonding strength, laser surface treatment, PEKK, titanium alloy.

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Authors: A. M. Alaskari, S. E. Oraby

Abstract:

The quality of a machined surface is becoming more and more important to justify the increasing demands of sophisticated component performance, longevity, and reliability. Usually, any machining operation leaves its own characteristic evidence on the machined surface in the form of finely spaced micro irregularities (surface roughness) left by the associated indeterministic characteristics of the different elements of the system: tool-machineworkpart- cutting parameters. However, one of the most influential sources in machining affecting surface roughness is the instantaneous state of tool edge. The main objective of the current work is to relate the in-process immeasurable cutting edge deformation and surface roughness to a more reliable easy-to-measure force signals using a robust non-linear time-dependent modeling regression techniques. Time-dependent modeling is beneficial when modern machining systems, such as adaptive control techniques are considered, where the state of the machined surface and the health of the cutting edge are monitored, assessed and controlled online using realtime information provided by the variability encountered in the measured force signals. Correlation between wear propagation and roughness variation is developed throughout the different edge lifetimes. The surface roughness is further evaluated in the light of the variation in both the static and the dynamic force signals. Consistent correlation is found between surface roughness variation and tool wear progress within its initial and constant regions. At the first few seconds of cutting, expected and well known trend of the effect of the cutting parameters is observed. Surface roughness is positively influenced by the level of the feed rate and negatively by the cutting speed. As cutting continues, roughness is affected, to different extents, by the rather localized wear modes either on the tool nose or on its flank areas. Moreover, it seems that roughness varies as wear attitude transfers from one mode to another and, in general, it is shown that it is improved as wear increases but with possible corresponding workpart dimensional inaccuracy. The dynamic force signals are found reasonably sensitive to simulate either the progressive or the random modes of tool edge deformation. While the frictional force components, feeding and radial, are found informative regarding progressive wear modes, the vertical (power) components is found more representative carrier to system instability resulting from the edge-s random deformation.

Keywords: Dynamic force signals, surface roughness (finish), tool wear and deformation, tool wear modes (nose, flank)

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Authors: Tomas Luneckas, Dainius Udris

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In this paper a simple terrain evaluation method for hexapod robot is introduced. This method is based on feet coordinate evaluation when all are on the ground. Depending on the feet coordinate differences the local terrain evaluation is possible. Terrain evaluation is necessary for right gait selection and/or body position correction. For terrain roughness evaluation three planes are plotted: two of them as definition points use opposite feet coordinates, third coincides with the robot body plane. The leaning angle of body plane is evaluated measuring gravity force using three-axis accelerometer. Terrain roughness evaluation method is based on angle estimation between normal vectors of these planes. Aim of this work is to present a simple method for embedded robot controller, allowing to find the best further movement settings.

Keywords: Hexapod robot, pose estimation, terrain evaluation, terrain roughness.

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Authors: Elham Farahmand, Fatimah Ibrahim, Samira Hosseini, Ivan Djordjevic, Leo. H. Koole

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Compositions of different molar ratios of polymethylmethacrylate-co-methacrylic acid (PMMA-co-MAA) were synthesized via free-radical polymerization. Polymer coated surfaces have been produced on silicon wafers. Coated samples were analyzed by atomic force microscopy (AFM). The results have shown that the roughness of the surfaces have increased by increasing the molar ratio of monomer methacrylic acid (MAA). This study reveals that the gradual increase in surface roughness is due to the fact that carboxylic functional groups have been generated by MAA segments. Such surfaces can be desirable platforms for fabrication of the biosensors for detection of the viruses and diseases.

Keywords: Polymethylmethacrylate-co-methacrylic acid (PMMA-co-MAA), Polymeric material, Atomic Force Microscopy, roughness, carboxylic functional groups.

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Authors: Kamran Turkoglu, Ugur Ozdemir, Melike Nikbay, Elbrous M. Jafarov

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In this paper, an automatic control system design based on Integral Squared Error (ISE) parameter optimization technique has been implemented on longitudinal flight dynamics of an UAV. It has been aimed to minimize the error function between the reference signal and the output of the plant. In the following parts, objective function has been defined with respect to error dynamics. An unconstrained optimization problem has been solved analytically by using necessary and sufficient conditions of optimality, optimum PID parameters have been obtained and implemented in control system dynamics.

Keywords: Optimum Design, KKT Conditions, UAV, Longitudinal Flight Dynamics, ISE Parameter Optimization.

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Authors: Farhad Kolahan, Mohsen Manoochehri, Abbas Hosseini

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Machining is an important manufacturing process used to produce a wide variety of metallic parts. Among various machining processes, turning is one of the most important one which is employed to shape cylindrical parts. In turning, the quality of finished product is measured in terms of surface roughness. In turn, surface quality is determined by machining parameters and tool geometry specifications. The main objective of this study is to simultaneously model and optimize machining parameters and tool geometry in order to improve the surface roughness for AISI1045 steel. Several levels of machining parameters and tool geometry specifications are considered as input parameters. The surface roughness is selected as process output measure of performance. A Taguchi approach is employed to gather experimental data. Then, based on signal-to-noise (S/N) ratio, the best sets of cutting parameters and tool geometry specifications have been determined. Using these parameters values, the surface roughness of AISI1045 steel parts may be minimized. Experimental results are provided to illustrate the effectiveness of the proposed approach.

Keywords: Taguchi method, turning parameters, tool geometry specifications, S/N ratio, statistical analysis.

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Authors: M. A. Kamely, A. Y. Bani Hashim, S. H. Yahaya, H. Sihombing, H. Hazman

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Grinding requires high specific energy and the consequent development of high temperature at tool-workpiece contact zone impairs workpiece quality by inducing thermal damage to the surface. Finishing grinding process requires component to be cut more than one pass. This paper deals with an investigation on the effect of multipass cutting on grinding performance in term of surface roughness and surface defect. An experimental set-up has been developed for this and a detailed comparison has been done with a single pass and various numbers of cutting pass. Results showed that surface roughness increase with the increase in a number of cutting pass. Good surface finish of 0.26μm was obtained for single pass cutting and 0.73μm for twenty pass cutting. It was also observed that the thickness of the white layer increased with the increased in a number of cutting pass.

Keywords: Cylindrical grinding, Multipass cutting, Surface roughness, Surface defect.

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Authors: P Chockalingam, K Kok, R Vijayaram

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This paper presents a comparative study on dry and wet grinding through experimental investigation in the grinding of CSM glass fibre reinforced polymer laminates using a pink aluminium oxide wheel. Different sets of experiments were performed to study the effects of the independent grinding parameters such as grinding wheel speed, feed and depth of cut on dependent performance criteria such as cutting forces and surface finish. Experimental conditions were laid out using design of experiment central composite design. An effective coolant was sought in this study to minimise cutting forces and surface roughness for GFRP laminates grinding. Test results showed that the use of coolants reduces surface roughness, although not necessarily the cutting forces. These research findings provide useful economic machining solution in terms of optimized grinding conditions for grinding CSM GFRP.

Keywords: Chopped Strand Mat GFRP laminates, Dry and Wet Grinding, Cutting Forces, Surface Finish.

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Authors: Dejan Tanikić, Jelena Đoković, Saša Kalinović, Miodrag Manić, Saša Ranđelović

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This paper deals with measuring and modelling of the quality of the machined surface of the metal machining process. The average surface roughness (R_a) which represents the quality of the machined part was measured during the dry turning of the AISI 4140 steel. A large number of factors with the unknown relations among them influences this parameter, and that is why mathematical modelling is extremely complicated. Different values of cutting speed, feed rate, depth of cut (cutting regime) and workpiece hardness causes different surface roughness values. Modelling with soft computing techniques may be very useful in such cases. This paper presents the usage of the fuzzy logic-based system for determining metal machining process parameter in order to find the proper values of cutting regimes.

Keywords: Metal machining, surface roughness, fuzzy logic, process modelling.

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Authors: S. Ghorbani, N. I. Polushin

Abstract:

The machinability of workpieces (AISI 1045 Steel, AA2024 aluminum alloy, A48-class30 gray cast iron) in turning operation has been carried out using different types of cutting tool (conventional, cutting tool with holes in toolholder and cutting tool filled up with composite material) under dry conditions on a turning machine at different stages of spindle speed (630-1000 rpm), feed rate (0.05-0.075 mm/rev), depth of cut (0.05-0.15 mm) and tool overhang (41-65 mm). Experimentation was performed as per Taguchi’s orthogonal array. To evaluate the relative importance of factors affecting surface roughness the single decision tree (SDT), Decision tree forest (DTF) and Group method of data handling (GMDH) were applied.

Keywords: Decision Tree Forest, GMDH, surface roughness, taguchi method, turning process.

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Authors: Gabi N. Nehme, Saeed Ghalambor

Abstract:

The use of titanium fluoride and iron fluoride (TiF3/FeF3) catalysts in combination with polutetrafluoroethylene (PTFE) in plain zinc- dialkyldithiophosphate (ZDDP) oil is important for the study of engine tribocomponents and is increasingly a strategy to improve the formation of tribofilm and provide low friction and excellent wear protection in reduced phosphorus plain ZDDP oil. The influence of surface roughness and the concentration of TiF3/FeF3/PTFE were investigated using bearing steel samples dipped in lubricant solution at 100°C for two different heating time durations. This paper addresses the effects of water drop contact angle using different surface; finishes after treating them with different lubricant combination. The calculated water drop contact angles were analyzed using Design of Experiment software (DOE) and it was determined that a 0.05 μm Ra surface roughness would provide an excellent TiF3/FeF3/PTFE coating for antiwear resistance as reflected in the Scanning electron microscopy (SEM) images and the tribological testing under extreme pressure conditions. Both friction and wear performance depend greatly on the PTFE/and catalysts in plain ZDDP oil with 0.05 % phosphorous and on the surface finish of bearing steel. The friction and wear reducing effects, which was observed in the tribological tests, indicated a better micro lubrication effect of the 0.05 μm Ra surface roughness treated at 100°C for 24 hours when compared to the 0.1 μm Ra surface roughness with the same treatment.

Keywords: Scanning Electron Microscopy (SEM), ZDDP, catalysts, PTFE, friction, wear.

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