Search results for: surface plasmon polariton.

Authors: Joseph C. Chen, Joshua Cox

Abstract:

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, dimensional accuracy, Wire EDM.

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Authors: R. Hela, L. Bodnarova

Abstract:

Paper focuses on experimental testing of possibilities of mechanical activation of fly ash and observation of influence of specific surface and granulometry on final properties of fresh and hardened concrete. Mechanical grinding prepared various fineness of fly ash, which was classed by specific surface in accordance with Blain and their granulometry was determined by means of laser granulometer. Then, sets of testing specimens were made from mix designs of identical composition with 25% or Portland cement CEM I 42.5 R replaced with fly ash with various specific surface and granulometry. Mix design with only Portland cement was used as reference. Mix designs were tested on consistency of fresh concrete and compressive strength after 7, 28, 60 and 90 days.

Keywords: Concrete, fly ash, latent hydraulicity, mechanically activated fly ash.

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Authors: Yi Xu, Zexiang Li

Abstract:

In inspection and workpiece localization, sampling point data is an important issue. Since the devices for sampling only sample discrete points, not the completely surface, sampling size and location of the points will be taken into consideration. In this paper a method is presented for determining the sampled points size and location for achieving efficient sampling. Firstly, uncertainty analysis of the localization parameters is investigated. A localization uncertainty model is developed to predict the uncertainty of the localization process. Using this model the minimum size of the sampled points is predicted. Secondly, based on the algebra theory an eigenvalue-optimal optimization is proposed. Then a freeform surface is used in the simulation. The proposed optimization is implemented. The simulation result shows its effectivity.

Keywords: eigenvalue-optimal optimization, freeform surface inspection, sampling size and location, sampled points.

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Authors: A. Manallah, C. Meier

Abstract:

Confocal spectral interferometry (CSI) is an innovative optical method for determining microtopography of surfaces and thickness of transparent layers, based on the combination of two optical principles: confocal imaging, and spectral interferometry. Confocal optical system images at each instant a single point of the sample. The whole surface is reconstructed by plan scanning. The interference signal generated by mixing two white-light beams is analyzed using a spectrometer. In this work, five ‘rugotests’ of known standard roughnesses are investigated. The topography is then measured and illustrated, and the equivalent roughness is determined and compared with the standard values.

Keywords: Confocal spectral interferometry, Nondestructive testing, Optical metrology, Surface topography, Roughness.

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Authors: Abinash Tripathy, Girish Muralidharan, Amitava Pramanik, Prosenjit Sen

Abstract:

Superhydrophobic surfaces are abundant in nature. Several surfaces such as wings of butterfly, legs of water strider, feet of gecko and the lotus leaf show extreme water repellence behaviour. Self-cleaning, stain-free fabrics, spill-resistant protective wears, drag reduction in micro-fluidic devices etc. are few applications of superhydrophobic surfaces. In order to design robust superhydrophobic surface, it is important to understand the interaction of water with superhydrophobic surface textures. In this work, we report a simple coating method for creating large-scale flexible superhydrophobic paper surface. The surface consists of multiple layers of silanized zirconia microparticles decorated with zirconia nanoparticles. Water contact angle as high as 159±1⁰ and contact angle hysteresis less than 8⁰ was observed. Drop impact studies on superhydrophobic paper surface were carried out by impinging water droplet and capturing its dynamics through high speed imaging. During the drop impact, the Weber number was varied from 20 to 80 by altering the impact velocity of the drop and the parameters such as contact time, normalized spread diameter were obtained. In contrast to earlier literature reports, we observed contact time to be dependent on impact velocity on superhydrophobic surface. Total contact time was split into two components as spread time and recoil time. The recoil time was found to be dependent on the impact velocity while the spread time on the surface did not show much variation with the impact velocity. Further, normalized spreading parameter was found to increase with increase in impact velocity.

Keywords: Contact angle, contact angle hysteresis, contact time, superhydrophobic.

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Authors: G. T. Ramos-Escobedo, E. T. Pecina-Treviño, L. F. Camacho-Ortegon, E. Orrantia-Borunda

Abstract:

The mineral bioflotation represents a viable alternative for the evaluation of new processes benefit alternative. The adsorption bacteria on minerals surfaces will depend mainly on the type of the microorganism as well as of the studied mineral surface. In the current study, adhesion of S. carnosus on coal was studied. Several methods were used as: DRX, Fourier Transform Infra-Red (FTIR) adhesion isotherms and kinetic. The main goal is to recovery of organic matter by the microflotation process on coal particles with biological reagent (S. carnosus). Adhesion tests revealed that adhesion took place after of 8 h at pH 9. The results suggest that the adhesion of bacteria to solid substrates can be considered an abiotic physicochemical process that is consequently governed by bacterial surface properties such as their specific surface area, hydrophobicity and surface functionalities. The greatest coal fine flotability was of 75%, after 5 min of flotation.

Keywords: Fine Coal, Bacteria, Adhesion, recovery matter organic.

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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: M. Bougamouza, M. Bouhadef, T. Zitoun

Abstract:

The aim of this study is to examine, through experimentation in the laboratory, the supercritical flow in the presence of an obstacle in a rectangular channel. The supercritical regime in the whole hydraulic channel is achieved by adding a convergent. We will observe the influence of the obstacle shape and dimension on the characteristics of the supercritical flow, mainly the free-surface elevation and the velocity profile. The velocity measurements have been conducted with the one dimension laser anemometry technique.

Keywords: Experiments, free-surface flow, hydraulic channel, uneven bottom, laser anemometry, supercritical regime.

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Authors: H. M. Mohammad, A. Martin, N. Brown, N. Hodson, P. Hill, E. Roberts

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Graphite intercalation compound (GIC) has been demonstrated to be a useful, low capacity and rapid adsorbent for the removal of organic micropollutants from water. The high electrical conductivity and low capacity of the material lends itself to electrochemical regeneration. Following electrochemical regeneration, equilibrium loading under similar conditions is reported to exceed that achieved by the fresh adsorbent. This behavior is reported in terms of the regeneration efficiency being greater than 100%. In this work, surface analysis techniques are employed to investigate the material in three states: ‘Fresh’, ‘Loaded’ and ‘Regenerated’. ‘Fresh’ GIC is shown to exhibit a hydrogen and oxygen rich surface layer approximately 150 nm thick. ‘Loaded’ GIC shows a similar but slightly thicker surface layer (approximately 370 nm thick) and significant enhancement in the hydrogen and oxygen abundance extending beyond 600 nm from the surface. 'Regenerated’ GIC shows an oxygen rich layer, slightly thicker than the fresh case at approximately 220 nm while showing a very much lower hydrogen enrichment at the surface. Results demonstrate that while the electrochemical regeneration effectively removes the phenol model pollutant, it also oxidizes the exposed carbon surface. These results may have a significant impact on the estimation of adsorbent life.

Keywords: Graphite, adsorbent, electrochemical, regeneration, phenol.

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Authors: S.Thong-Om, W. Payakcho, J. Grasasom, A. Oonsivilaiand B. Marungsri

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This paper presents the comparison ageing deterioration of silicone rubber housing material for outdoor polymer insulators by using salt fog ageing test based on IEC 61109 and outdoor exposure test.Four types of high temperature silicone vulcanized silicone rubber sheet with different amount of ATH were used as testing specimen. For salt fog ageing test, the specimens were tested continuously 1000 hours with energized in test chamber. For outdoor exposure test, the specimens were hung continuously 18 months without energized. Physical and chemical analyses were conducted to evaluate degree of ageing deterioration of tested specimens. Slightly surface erosion was observed on specimen surface after salt fog ageing test and no erosion was observed on surface of outdoor exposure specimen. However, comparable degree of ageing deterioration can be seen from surface analysis results.

Keywords: Accelerated ageing test, outdoor exposure test, HTV silicone rubber, housing material, salt fog test, surface erosion, polymer insulator

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Authors: Afshin Ahmadi Nadooshan

Abstract:

In this article, various models of surface tension force (CSF, CSS and PCIL) for interfacial flows have been applied to dynamic case and the results were compared. We studied the Kelvin- Helmholtz instabilities, which are produced by shear at the interface between two fluids with different physical properties. The velocity inlet is defined as a sinusoidal perturbation. When gravity and surface tension are taking into account, we observe the development of the Instability for a critic value of the difference of velocity of the both fluids. The VOF Model enables to simulate Kelvin-Helmholtz Instability as dynamic case.

Keywords: Interfacial flow, Incompressible flow, surface tension, Volume-Of-Fluid, Kelvin-Helmholtz.

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Authors: Mahmoud Zarrini, R.N. Pralhad

Abstract:

In this chapter, we have studied Variation of velocity in incompressible fluid over a moving surface. The boundary layer equations are on a fixed or continuously moving flat plate in the same or opposite direction to the free stream with suction and injection. The boundary layer equations are transferred from partial differential equations to ordinary differential equations. Numerical solutions are obtained by using Runge-Kutta and Shooting methods. We have found numerical solution to velocity and skin friction coefficient.

Keywords: Boundary layer, continuously moving surface, shooting method, skin friction coefficient.

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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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Authors: Janisse Vivas, Doug Stead, Davide Elmo, Charles Hunt

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This paper presents the results of a study on the influence of varying percentages of rock bridges along a basal surface defining a biplanar failure mode. A pseudo-coupled-hydromechanical brittle fracture analysis is adopted using the state-of-the-art code Slope Model. Model results show that rock bridge failure is strongly influenced by the incorporation of groundwater pressures. The models show that groundwater pressure can promote total failure of a 5% rock bridge along the basal surface. Once the percentage of the rock bridges increases to 10 and 15%, although, the rock bridges are broken, full interconnection of the surface defining the basal surface of the biplanar mode does not occur. Increased damage is caused when the rock bridge is located at the daylighting end of the basal surface in proximity to the blast damage zone. As expected, some cracking damage is experienced in the blast damage zone, where properties representing a good quality controlled damage blast technique were assumed. Model results indicate the potential increase of permeability towards the blast damage zone.

Keywords: Slope model, lattice spring, blasting damage zone.

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Authors: M. Raciti Castelli, M. Cescon, E. Benini

Abstract:

Nuclear energy sources have been widely used in the past decades in order to power spacecraft subsystems. Nevertheless, their use has attracted controversy because of the risk of harmful material released into the atmosphere if an accident were to occur during the launch phase of the mission, leading to the general adoption of photovoltaic systems. As compared to solar cells, wind turbines have a great advantage on Mars, as they can continuously produce power both during dust storms and at night-time: this paper focuses on the potential of a wind energy conversion system (WECS) considering the atmospheric conditions on Mars. Wind potential on Martian surface has been estimated, as well as the average energy requirements of a Martian probe or surface rover. Finally, the expected daily energy output of the WECS has been computed on the basis of both the swept area of the rotor and the equivalent wind speed at the landing site.

Keywords: Wind turbine, wind potential, Mars, probe, surface rover.

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Authors: Dariush Semnani, Hossein Ghayoor

Abstract:

In this paper a novel method was presented for evaluating the fabric pills using digital image processing techniques. This work provides a novel technique for detecting pills and also measuring their heights, surfaces and volumes. Surely, measuring the intensity of defects by human vision is an inaccurate method for quality control; as a result, this problem became a motivation for employing digital image processing techniques for detection of defects of fabric surface. In the former works, the systems were just limited to measuring of the surface of defects, but in the presented method the height and the volume of defects were also measured, which leads to a more accurate quality control. An algorithm was developed to first, find pills and then measure their average intensity by using three criteria of height, surface and volume. The results showed a meaningful relation between the number of rotations and the quality of pilled fabrics.

Keywords: 3D analysis, computer vision, fabric, pile, surface evaluation

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Authors: Nguyen Thi Thanh Truc, Chi-Hyeon Lee, Byeong-Kyu Lee, Srinivasa Reddy Mallampati

Abstract:

This study evaluated to facilitate separation of ABS plastics from other waste plastics by froth flotation after surface hydrophilization of ABS with heat treatment. The mild heat treatment at 100oC for 60s could selectively increase the hydrophilicity of the ABS plastics surface (i.e., ABS contact angle decreased from 79o to 65.8o) among other plastics mixture. The SEM and XPS results of plastic samples sufficiently supported the increase in hydrophilic functional groups and decrease contact angle on ABS surface, after heat treatment. As a result of the froth flotation (at mixing speed 150 rpm and airflow rate 0.3 L/min) after heat treatment, about 85% of ABS was selectively separated from other heavy plastics with 100% of purity. The effect of optimum treatment condition and detailed mechanism onto separation efficiency in the froth floatation was also investigated. This research is successful in giving a simple, effective, and inexpensive method for ABS separation from waste plastics.

Keywords: ABS, hydrophilic, heat treatment, froth flotation, contact angle.

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Authors: S.Asadi, H.Panahi

Abstract:

The Navier–Stokes equations for unsteady, incompressible, viscous fluids in the axisymmetric coordinate system are solved using a control volume method. The volume-of-fluid (VOF) technique is used to track the free-surface of the liquid. Model predictions are in good agreement with experimental measurements. It is found that the dynamic processes after impact are sensitive to the initial droplet velocity and the liquid pool depth. The time evolution of the crown height and diameter are obtained by numerical simulation. The critical We number for splashing (Wecr) is studied for Oh (Ohnesorge) numbers in the range of 0.01~0.1; the results compares well with those of the experiments.

Keywords: Droplet impingement, free surface flows, liquid crown, numerical simulation, thin liquid film.

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Authors: Josef Sepitka, Petr Vlcak, Tomas Horazdovsky, Vratislav Perina

Abstract:

An ion implantation technique was used for designing the surface area of a titanium alloy and for irradiation-enhanced hardening of the surface. The Ti6Al4V alloy was treated by nitrogen ion implantation at fluences of 2·10¹⁷ and 4·10¹⁷ cm^-2 and at ion energy 90 keV. The depth distribution of the nitrogen was investigated by Rutherford Backscattering Spectroscopy. The gradient of mechanical properties was investigated by nanoindentation. The continuous measurement mode was used to obtain depth profiles of the indentation hardness and the reduced storage modulus of the modified surface area. The reduced storage modulus and the hardness increase with increasing fluence. Increased fluence shifts the peak of the mechanical properties as well as the peak of nitrogen concentration towards to the surface. This effect suggests a direct relationship between mechanical properties and nitrogen distribution.

Keywords: Nitrogen ion implantation, titanium-based nanolayer, storage modulus, hardness, microstructure.

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Authors: Osama A. Terfas, Abdusalam A. Alaktiwi

Abstract:

Pressure vessels are usually operating at temperatures where the conditions of linear elastic fracture mechanics are no longer met because massive plasticity precedes crack propagation. In this work the development of a surface crack in a pressure vessel subject to bending and tension under elastic-plastic fracture mechanics conditions was investigated. Finite element analysis was used to evaluate the hydrostatic stress, the J-integral and crack growth for semi-elliptical surface-breaking cracks. The results showed non-uniform stress triaxiality and crack driving force around the crack front at large deformation levels. Different ductile crack extensions were observed which emphasis the dependent of ductile tearing on crack geometry and type of loading. In bending the crack grew only beneath the surface, and growth was suppressed at the deepest segment. This contrasts to tension where the crack breaks through the thickness with uniform growth along the entire crack front except at the free surface. Current investigations showed that the crack growth developed under linear elastic fracture mechanics conditions will no longer be applicable under ductile tearing scenarios.

Keywords: Bending, ductile tearing, fracture toughness, stress triaxiality, tension.

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Authors: Farhad Kolahan, Mohsen Manoochehri, Abbas Hosseini

Abstract:

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: S. Gao, S. Srirattayawong

Abstract:

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: S. F. Wong, S. S. Dol

Abstract:

Automotive designers have been trying to use dimples to reduce drag in vehicles. In this work, a car model has been applied with dimple surface with a parameter called dimple ratio DR, the ratio between the depths of the half dimple over the print diameter of the dimple, has been introduced and numerically simulated via k-ε turbulence model to study the aerodynamics performance with the increasing depth of the dimples The Ahmed body car model with 25 degree slant angle is simulated with the DR of 0.05, 0.2, 0.3 0.4 and 0.5 at Reynolds number of 176387 based on the frontal area of the car model. The geometry of dimple changes the kinematics and dynamics of flow. Complex interaction between the turbulent fluctuating flow and the mean flow escalates the turbulence quantities. The maximum level of turbulent kinetic energy occurs at DR = 0.4. It can be concluded that the dimples have generated extra turbulence energy at the surface and as a result, the application of dimples manages to reduce the drag coefficient of the car model compared to the model with smooth surface.

Keywords: Aerodynamics, Boundary Layer, Dimple, Drag, Kinetic Energy, Turbulence.

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Authors: Wen-Haw Chen, Sheng-Gwo Chen

Abstract:

The distance between two objects is an important problem in CAGD, CAD and CG etc. It will be presented in this paper that a simple and quick method to estimate the distance between a point and a Bezier curve on a Bezier surface.

Keywords: Geodesic-like curve, distance, projection, Bezier.

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Authors: Abegunde Linda, Adedeji Oluwatola

Abstract:

It has become an increasing evident that large development influences the climate. There are concerns that rising temperature over developed areas could have negative impact and increase living discomfort within city boundaries. Temperature trends in Ibadan city have received little attention, yet the area has experienced heavy urban expansion between 1972 and 2014. This research aims at examining the impact of landuse change on surface temperature knowing that the built-up environment absorb and store solar energy, resulting into the Urban Heat Island (UHI) effect. The Landsat imagery was used to examine the landuse change for a period of 42 years (1972-2014). Land Surface Temperature (LST) was obtained by converting the thermal band to a surface temperature map and zonal statistic analyses was used to examine the relationship between landuse and temperature emission. The results showed that the settlement area increased to a large extent while the area covered by vegetation reduced during the study period. The spatial and temporal trends of surface temperature are related to the gradual change in urban landuse/landcover and the settlement area has the highest emission. This research provides useful insight into the temporal behavior of the Ibadan city.

Keywords: Landuse, LST, Remote sensing, UHI.

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Authors: R. Manimaran

Abstract:

CFD simulations are carried out in arterial stenoses with 48 % areal occlusion. Non-newtonian fluid model is selected for the blood flow as the same problem has been solved before with Newtonian fluid model. Studies on flow resistance with the presence of surface irregularities are carried out. Investigations are also performed on the pressure drop at various Reynolds numbers. The present study revealed that the pressure drop across a stenosed artery is practically unaffected by surface irregularities at low Reynolds numbers, while flow features are observed and discussed at higher Reynolds numbers.

Keywords: Blood flow, Roughness, Computational fluid dynamics, Bio fluid mechanics.

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Authors: Wei Zha, Jingzeng Zhang, Chen Zhao, Ran Cai, Xueyuan Nie

Abstract:

Cathodic plasma electrolysis (CPE) is used to create surface textures on cast iron samples for improving the tribological properties. Micro craters with confined size distribution were successfully formed by CPE process. These craters can generate extra hydrodynamic pressure that separates two sliding surfaces, increase the oil film thickness and accelerate the transition from boundary to mixed lubrication. It was found that the optimal crater size was 1.7 μm, at which the maximum lubrication efficiency was achieved. The Taguchi method was used to optimize the process parameters (voltage and roughness) for CPE surface texturing. The orthogonal array and the signal-to-noise ratio were employed to study the effect of each process parameter on the coefficient of friction. The results showed that with higher voltage and lower roughness, the lower friction coefficient can be obtained, and thus the lubrication can be more efficiently used for friction reduction.

Keywords: Cathodic plasma electrolysis, friction, lubrication, plasma surface texturing.

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Authors: Pavana Manvikar, G K Purohit

Abstract:

The functional performance of machined components, often, depends on surface topography, hardness, nature of stress and strain induced on the surface, etc. Invariably, surfaces of metallic components obtained by turning, milling, etc., consist of irregularities such as machining marks are responsible for the above. Surface finishing/coating processes used to produce improved surface quality/textures are classified as chip-removal and chip-less processes. Burnishing is chip-less cold working process carried out to improve surface finish, hardness and resistance to fatigue and corrosion; not obtainable by other surface coating and surface treatment processes. It is a very simple, but effective method which improves surface characteristics and is reported to introduce compressive stresses.

Of late, considerable attention is paid to post-machining, finishing operations, such as burnishing. During burnishing the micro-irregularities start to deform plastically, initially the crests are gradually flattened and zones of reduced deformation are formed. When all the crests are deformed, the valleys between the micro-irregularities start moving in the direction of the newly formed surface. The grain structure is then condensed, producing a smoother and harder surface with superior load-carrying and wear-resistant capabilities.

Burnishing can be performed on a lathe with a highly polished ball or roller type tool which is traversed under force over a rotating/stationary work piece. Often, several passes are used to obtain the work piece surface with the desired finish and hardness.

This paper presents the findings of an experimental investigation on the effect of ball burnishing parameters such as, burnishing speed, feed, force and number of passes; on surface roughness (Ra) and micro-hardness (Hv) of a 60/40 copper/zinc alloy, using a 2-level fractional factorial design of experiments (DoE). Mathematical models were developed to predict surface roughness and hardness generated by burnishing in terms of the above process parameters. A ball-type tool, designed and constructed from a high chrome steel material (HR_C=63 and Ra=0.012 µm), was used for burnishing of fine-turned cylindrical bars (0.68-0.78µm and 145Hv). They are given by,

 

Ra= 0.305-0.005X₁ - 0.0175X₂ + 0.0525X₄ + 0.0125X₁X₄ -0.02X₂X₄ - 0.0375X₃X₄

 

Hv=160.625 -2.37 5X₁ + 5.125X₂ + 1.875X₃ + 4.375X₄ - 1.625X₁X₄ + 4.375X₂X₄ - 2.375X₃X₄

 

High surface microhardness (175H_V) was obtained at 400rpm, 2passes, 0.05mm/rev and 15kgf., and high surface finish (0.20µm) was achieved at 30kgf, 0.1mm/rev, 112rpm and single pass. In other words, surface finish improved by 350% and microhardness improved by 21% compared to as machined conditions.

Keywords: Ball burnishing, surface roughness, micro-hardness.

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Authors: A. Razavykia, A. Esmaeilzadeh, S. Iranmanesh

Abstract:

Many orthopedic implants like proximal humerus cases require lower surface roughness and almost immediate/short lead time surgery. Thus, rapid response from the manufacturer is very crucial. Tool path strategy of milling process has a direct influence on the surface roughness and lead time of medical implant. High-speed milling as promised process would improve the machined surface quality, but conventional or super-abrasive grinding still required which imposes some drawbacks such as additional costs and time. Currently, many CAD/CAM software offers some different tool path strategies to milling free form surfaces. Nevertheless, the users must identify how to choose the strategies according to cutting tool geometry, geometry complexity, and their effects on the machined surface. This study investigates the effect of different tool path strategies for milling a proximal humerus head during finishing operation on stainless steel 316L. Experiments have been performed using MAHO MH700 S vertical milling machine and four machining strategies, namely, spiral outward, spiral inward, and radial as well as zig-zag. In all cases, the obtained surfaces were analyzed in terms of roughness and dimension accuracy compared with those obtained by simulation. The findings provide evidence that surface roughness, dimensional accuracy, and machining time have been affected by the considered tool path strategy.

Keywords: CAD/CAM software, milling, orthopedic implants, tool path strategy.

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Authors: I. Tiryakioglu, M. A. Ugur, C. Ozkaymak

Abstract:

The development of Global Navigation Satellite System (GNSS) technology has led to increasingly widely and successful applications of GNSS surveys for monitoring crustal movements. Instead of the multi-period GNSS solutions, this study utilizes GNSS time series that are required to more precisely determine the vertical deformations in the study area. In recent years, the surface deformations that are parallel and semi-parallel to Bolvadin fault have occurred in Western Anatolia. These surface deformations have continued to occur in Bolvadin settlement area that is located mostly on alluvium ground. Due to these surface deformations, a number of cracks in the buildings located in the residential areas and breaks in underground water and sewage systems have been observed. In order to determine the amount of vertical surface deformations, two continuous GNSS stations have been established in the region. The stations have been operating since 2015 and 2017, respectively. In this study, GNSS observations from the mentioned two GNSS stations were processed with GAMIT/GLOBK (GNSS Analysis Massachusetts Institute of Technology/GLOBal Kalman) program package to create coordinate time series. With the time series analyses, the GNSS stations’ behaviour models (linear, periodical, etc.), the causes of these behaviours, and mathematical models were determined. The study results from the time series analysis of these two 2 GNSS stations show approximately 50-90 mm/yr vertical movement.

Keywords: Bolvadin fault, GAMIT, GNSS time series, surface deformations.

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