Search results for: Surface Roughness (SR)

Authors: Gurinder Singh Brar, Sarbjeet Singh, Harry Garg

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Wire Electric Discharge Machining (WEDM) is thermal machining process capable of machining very hard electrically conductive material irrespective of their hardness. WEDM is being widely used to machine micro scale parts with the high dimensional accuracy and surface finish. The objective of this paper is to optimize the process parameters of wire EDM to fabricate the micro channels and to calculate the surface finish and material removal rate of micro channels fabricated using wire EDM. The material used is aluminum 6061 alloy. The experiments were performed using CNC wire cut electric discharge machine. The effect of various parameters of WEDM like pulse on time (TON) with the levels (100, 150, 200), pulse off time (TOFF) with the levels (25, 35, 45) and current (IP) with the levels (105, 110, 115) were investigated to study the effect on output parameter i.e. Surface Roughness and Material Removal Rate (MRR). Each experiment was conducted under different conditions of pulse on time, pulse off time and peak current. For material removal rate, TON and Ip were the most significant process parameter. MRR increases with the increase in TON and Ip and decreases with the increase in TOFF. For surface roughness, TON and Ip have the maximum effect and TOFF was found out to be less effective.

Keywords: Micro Channels, Wire Electric Discharge Machining (WEDM), Metal Removal Rate (MRR), Surface Finish.

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Authors: Salah Gariani, Taher Dao, Ahmed Lajili

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This paper presents an experimental optimisation of surface roughness (Ra) and tool wear in the precision turning of AISI 304L alloy using a wiper and conventional cutting tools under wet cutting conditions. The machining trials were conducted based on Taguchi methodology employing an L9 orthogonal array design with four process parameters: feed rate, spindle speed, depth of cut, and cutting tool type. The experimental results were utilised to characterise the main factors affecting Ra and tool wear using the analyses of means (AOM) and variance (ANOVA). The results show that the wiper tools outperformed conventional tools in terms of surface quality and tool wear at optimal cutting conditions. The ANOVA results indicate that the main factors contributing to lower Ra are cutting tool type and feed rate, with percentage contribution ratios (PCRs) of 58.69% and 25.18% respectively. This confirms that tool type is the most significant factor affecting surface quality when turning AISI 304L. Additionally, a substantial reduction in tool wear was observed when a wiper insert was used, whereas noticeable increases in tool wear occurred when higher cutting speeds were employed for both tool types. These trends confirm the ANOVA outcomes that cutting speed has a significant effect on tool wear, with a PCR value of 39.22%, followed by tool type with a PCR of 27.40%. All machining trials generated similar continuous spiral or curl-shaped chips. A noticeable difference was found in the radius of the produced curl-shaped chips at different cutting speeds when turning AISI 304L under wet cutting conditions.

Keywords: AISI 304L alloy, conventional and wiper carbide tools, wet turning, average surface roughness, tool wear.

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Authors: Pushpendra S. Bharti, S. Maheshwari

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Electric discharge machining (EDM) is one of the most widely used non-conventional manufacturing process to shape difficult-to-cut materials. The process yield, in terms of material removal rate, surface roughness and tool wear rate, of EDM may considerably be improved by selecting the optimal combination(s) of process parameters. This paper employs Multi-response signal-to-noise (MRSN) ratio technique to find the optimal combination(s) of the process parameters during EDM of Inconel 718. Three cases v.i.z. high cutting efficiency, high surface finish, and normal machining have been taken and the optimal combinations of input parameters have been obtained for each case. Analysis of variance (ANOVA) has been employed to find the dominant parameter(s) in all three cases. The experimental verification of the obtained results has also been made. MRSN ratio technique found to be a simple and effective multi-objective optimization technique.

Keywords: EDM, material removal rate, multi-response signal-to-noise ratio, optimization, surface roughness.

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Authors: J. Kundrák, I. Sztankovics, K. Gyáni

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In addition to the increase of the material removal rate or surface rate, or the improvement of the surface quality, which are the main aims of the development of manufacturing technology, a growing number of other manufacturing requirements have appeared in the machining of workpiece surfaces. Among these it is becoming increasingly dominant to generate a surface topography in finishing operations which meets more closely the needs of operational requirements.

These include the examination of the surface periodicity and/or ensuring that the twist-structure values are within the limits (or even preventing its occurrence) in specified cases such as on the sealing surfaces of rotating shafts or on the inside working surfaces of needle roller bearings. In the view of the measurement the twist has different parameters from surface roughness, which must be determined for the machining procedures. Therefore in this paper the alteration of the theoretical values of the parameters determining twist structure are studied as a function of the kinematic properties.

Keywords: Kinematic parameters, rotational turning, surface topography, twist structure

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Authors: Samy E. Oraby, Ayman M. Alaskari

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In recent years, scanning probe atomic force microscopy SPM AFM has gained acceptance over a wide spectrum of research and science applications. Most fields focuses on physical, chemical, biological while less attention is devoted to manufacturing and machining aspects. The purpose of the current study is to assess the possible implementation of the SPM AFM features and its NanoScope software in general machining applications with special attention to the tribological aspects of cutting tool. The surface morphology of coated and uncoated as-received carbide inserts is examined, analyzed, and characterized through the determination of the appropriate scanning setting, the suitable data type imaging techniques and the most representative data analysis parameters using the MultiMode SPM AFM in contact mode. The NanoScope operating software is used to capture realtime three data types images: “Height", “Deflection" and “Friction". Three scan sizes are independently performed: 2, 6, and 12 μm with a 2.5 μm vertical range (Z). Offline mode analysis includes the determination of three functional topographical parameters: surface “Roughness", power spectral density “PSD" and “Section". The 12 μm scan size in association with “Height" imaging is found efficient to capture every tiny features and tribological aspects of the examined surface. Also, “Friction" analysis is found to produce a comprehensive explanation about the lateral characteristics of the scanned surface. Configuration of many surface defects and drawbacks has been precisely detected and analyzed.

Keywords: SPM AFM contact mode, carbide inserts, scan size, surface defects, surface roughness, PSD.

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Authors: M. R. Shabgard, B. Sadizadeh, H. Kakoulvand

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In the present work, a study has been made on the combination of the electrical discharge machining (EDM) with ultrasonic vibrations to improve the machining efficiency. In experiments the graphite used as tool electrode and material of workpiece was AISIH13 tool steel. The parameters such as discharge peak current and pulse duration were changed to explore their effect on the material removal rate (MRR), relative tool wear ratio (TWR) and surface roughness. From the experimental result it can be seen that ultrasonic vibration of the workpiece can significantly reduces the inactive pulses and improves the stability of process. It was found that ultrasonic assisted EDM (US-EDM) is effective in attaining a high material removal rate (MRR) in finishing regime.

Keywords: AISIH13 tool steel, Electrical discharge machining(EDM), Material removal rate (MRR), Surface roughness (Ra), Toolwear ratio (TWR), Ultrasonic assisted EDM (US-EDM)

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Authors: F. Rasi Marzabadi

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A series of experiments were carried out to study unsteady behavior of the flow field as well as the boundary layer of an airfoil oscillating in plunging motion in a subsonic wind tunnel. The measurements involved surface pressure distribution complimented with surface-mounted hot-films. The effect of leadingedge roughness that simulates surface irregularities on the wind turbine blades was also studied on variations of aerodynamic loads and boundary layer behavior.

Keywords: Boundary layer transition, plunging, reduced frequency, wind turbine.

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Authors: Manivannan A, Velmurugan M

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Solar air heater is a type of heat exchanger which transforms solar radiation into heat energy. The thermal performance of conventional solar air heater has been found to be poor because of the low convective heat transfer coefficient from the absorber plate to the air. It is attributed to the formation of a very thin boundary layer at the absorber plate surface commonly known as viscous sub-layer. Thermal efficiency of solar air heater can be improved by providing the artificial roughness on absorber plate is the most efficient technique. In this paper an attempt is made to provide artificial roughness by incorporating inclined multiple V-ribs in the underside of the absorber plate. 60˚V – ribs are arranged inclined to the direction of air flow. Performance of collector estimated theoretically and experimentally. Results of the investigation reveal that thermal efficiency of collector with multiple V-ribs increased by 14%.

Keywords: Artificial roughness, inclined multiple V-ribs, performance, Solar air collector.

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Authors: Jana Novakova, Lenka Petrkovska, Josef Brychta, Robert Cep, Lenka Ocenasova

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The contribution is dealing with the influence of high speed parameters on the quality of machined surface. In general the principle of high speed cutting lies in achieving faster machine times with concurrent increase in accuracy and quality of the machined areas in largely irregular, mathematically hard to define shapes. High speed machining is a highly effective method of machining with the following goals: increasing of machining productivity, increasing of quality of the machined surface, improving of machining economy, improving of ecological aspects of machining. This article is based on an experiment performed by the Department of Machining and Assembly of the Faculty of Mechanical Engineering of VŠBTechnical University of Ostrava.

Keywords: High speed cutting, measurement, surface integrity, surface roughness, residual stress/

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Authors: Chun-Ying Lee, Mei-Wen Wu, Li-Yi Cheng, Chiang-Ho Cheng

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This research studies the electroplating of zinc coating in the zinc chloride bath mixed with supercritical CO2. The sodium fluoride (NaF) was used as the bath additive to change the structure and property of the coating, and therefore the roughness and corrosion resistance of the zinc coating was investigated. The surface characterization was performed using optical microscope (OM), X-ray diffractometer (XRD), and α-step profilometer. Moreover, the potentiodynamic polarization measurement in 3% NaCl solution was employed in the corrosion resistance evaluation. Because of the emulsification of the electrolyte mixed in Sc-CO2, the electroplated zinc produced the coating with smoother surface, smaller grain, better throwing power and higher corrosion resistance. The main role played by the NaF was to reduce the coating’s roughness and grain size. In other words, the CO2 mixed with the electrolyte under the supercritical condition performed the similar function as brighter and leveler in zinc electroplating to enhance the throwing power and corrosion resistance of the coating.

Keywords: Supercritical CO2, zinc-electroplating, sodium fluoride.

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Authors: Rakesh Prajapati, Purvik Patel, Hardik Patel

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Productivity and quality are two important aspects that have become great concerns in today’s competitive global market. Every production/manufacturing unit mainly focuses on these areas in relation to the process, as well as the product developed. The electrical discharge machining (EDM) process, even now it is an experience process, wherein the selected parameters are still often far from the maximum, and at the same time selecting optimization parameters is costly and time consuming. Material Removal Rate (MRR) during the process has been considered as a productivity estimate with the aim to maximize it, with an intention of minimizing surface roughness taken as most important output parameter. These two opposites in nature requirements have been simultaneously satisfied by selecting an optimal process environment (optimal parameter setting). Objective function is obtained by Regression Analysis and Analysis of Variance. Then objective function is optimized using Genetic Algorithm technique. The model is shown to be effective; MRR and Surface Roughness improved using optimized machining parameters.

Keywords: Material removal rate, TWR, OC, DOE, ANOVA, MINITAB.

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Authors: Michael G. Danikas, Ramanujam Sarathi, Pavlos Ramnalis, Stefanos L. Nalmpantis

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This paper investigates the influence of various parameters on the behaviour of water droplets on polymeric surfaces under high electric fields. An inclined plane test was carried out to understand the droplet behaviour in strong electric field. Parameters such as water droplet conductivity, droplet volume, polymeric surface roughness and droplet positioning with respect to the electrodes were studied. The flashover voltage is affected by all aforementioned parameters. The droplet positioning is in some cases more vital than the droplet volume. Surface damages were analysed using Scanning Electron Microscopy (SEM) studies and by Energy dispersive X-ray Analysis (EDAX). It is observes that magnitude of discharge have direct influence on amount of surface da

Keywords: Water droplet, polymeric surface, hydrophobicity, partial discharges, SEM, EDAX.

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Authors: Shi-hong Lu, Chao-xun Liu, Yi-feng Zhu

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Ultrasonic shot peening (USP) on AALY12 sheet was studied. Several parameters (arc heights, surface roughness, surface topography and micro hardness) with different USP process parameters were measured. The research proposes that radius of curvature of shot peened sheet increases with time and electric current decreasing, while increases with pin diameter increasing, and radius of curvature reaches a saturation level after a specific processing time and electric current. An empirical model of the relationship between radius of curvature and pin diameter, electric current, time was also obtained. The research shows that the increment of surface and vertical micro hardness of material is more obvious with longer time and higher value of electric current, which can be up to 20% and 28% respectively.

Keywords: USP forming, surface properties, radius of curvature, residual stress.

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Authors: H. Soleimanjahi, M. J. Nategh, S. Falahi

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Deciding the numerous parameters involved in designing a competent artificial neural network is a complicated task. The existence of several options for selecting an appropriate architecture for neural network adds to this complexity, especially when different applications of heterogeneous natures are concerned. Two completely different applications in engineering and medical science were selected in the present study including prediction of workpiece's surface roughness in ultrasonic-vibration assisted turning and papilloma viruses oncogenicity. Several neural network architectures with different parameters were developed for each application and the results were compared. It was illustrated in this paper that some applications such as the first one mentioned above are apt to be modeled by a single network with sufficient accuracy, whereas others such as the second application can be best modeled by different expert networks for different ranges of output. Development of knowledge about the essentials of neural networks for different applications is regarded as the cornerstone of multidisciplinary network design programs to be developed as a means of reducing inconsistencies and the burden of the user intervention.

Keywords: Artificial Neural Network, Malignancy Diagnosis, Papilloma Viruses Oncogenicity, Surface Roughness, UltrasonicVibration-Assisted Turning.

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Authors: P. Slepicka, N. Slepickova Kasalkova, I. Michaljanicova, O. Nedela, Z. Kolska, V. Svorcik

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Polymers exposed to laser or plasma treatment or modified with different wet methods which enable the introduction of nanoparticles or biologically active species, such as amino-acids, may find many applications both as biocompatible or anti-bacterial materials or on the contrary, can be applied for a decrease in the number of cells on the treated surface which opens application in single cell units. For the experiments, two types of materials were chosen, a representative of non-biodegradable polymers, polyethersulphone (PES) and polyhydroxybutyrate (PHB) as biodegradable material. Exposure of solid substrate to laser well below the ablation threshold can lead to formation of various surface structures. The ripples have a period roughly comparable to the wavelength of the incident laser radiation, and their dimensions depend on many factors, such as chemical composition of the polymer substrate, laser wavelength and the angle of incidence. On the contrary, biopolymers may significantly change their surface roughness and thus influence cell compatibility. The focus was on the surface treatment of PES and PHB by pulse excimer KrF laser with wavelength of 248 nm. The changes of physicochemical properties, surface morphology, surface chemistry and ablation of exposed polymers were studied both for PES and PHB. Several analytical methods involving atomic force microscopy, gravimetry, scanning electron microscopy and others were used for the analysis of the treated surface. It was found that the combination of certain input parameters leads not only to the formation of optimal narrow pattern, but to the combination of a ripple and a wrinkle-like structure, which could be an optimal candidate for cell attachment. The interaction of different types of cells and their interactions with the laser exposed surface were studied. It was found that laser treatment contributes as a major factor for wettability/contact angle change. The combination of optimal laser energy and pulse number was used for the construction of a surface with an anti-cellular response. Due to the simple laser treatment, we were able to prepare a biopolymer surface with higher roughness and thus significantly influence the area of growth of different types of cells (U-2 OS cells).

Keywords: Polymer treatment, laser, periodic pattern, cell response.

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Authors: A. Alhazza, B. Alnaser

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Orthodontic restorative materials are widely used for the direct restoration of teeth or for cosmetic dentistry purposes. These materials have helped to solve many dental problems, providing healthy and beautiful smiles for many patients. In this study, we aimed to investigate whether the pH value has an effect on the surface structure of a nanohybrid composite material. Five different types of highly consumed beverages were selected to examine their effect on the surface structure of the nanohybrid composite material. The beverages had different pH values in the range of 3–6, i.e., they were all acidic. The material was investigated under the hardest conditions of surface exposure to the drinks by immersing the material for a long period. The specimens were examined using scanning electron microscopy (SEM) at different magnifications to investigate the effect of these beverages on the morphology of the nanohybrid composite material discs. All specimens showed an effect including pores, cracks, protrusions, and surface roughness as a result of the beverages. The degree of effect differed from one experimental group to another, but there was no relationship between the pH (acidity) value and the degree of effect on the surface structure of the specimens.

Keywords: Acidity, beverage, SEM, dentistry.

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Authors: Hisham M. Abourayana, Nuri A. Zreiba, Abdulkader M. Elamin

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Polymer-like organic thin films were deposited on both aluminum alloy type 6061 and glass substrates at room temperature by Plasma Enhanced Chemical Vapor Deposition (PECVD) methodusing benzene and hexamethyldisiloxane (HMDSO) as precursor materials. The surface and physical properties of plasma-polymerized organic thin films were investigated at different r.f. powers. The effects of benzene/argon ratio on the properties of plasma polymerized benzene films were also investigated. It is found that using benzene alone results in a non-coherent and non-adherent powdery deposited material. The chemical structure and surface properties of the asgrown plasma polymerized thin films were analyzed on glass substrates with FTIR and contact angle measurements. FTIR spectra of benzene deposited film indicated that the benzene rings are preserved when increasing benzene ratio and/or decreasing r.f. powers. FTIR spectra of HMDSO deposited films indicated an increase of the hydrogen concentration and a decrease of the oxygen concentration with the increase of r.f. power. The contact angle (θ) of the films prepared from benzene was found to increase by about 43% as benzene ratio increases from 10% to 20%. θ was then found to decrease to the original value (51°) when the benzene ratio increases to 100%. The contact angle, θ, for both benzene and HMDSO deposited films were found to increase with r.f. power. This signifies that the plasma polymerized organic films have substantially low surface energy as the r.f power increases. The corrosion resistance of aluminum alloy substrate both bare and covered with plasma polymerized thin films was carried out by potentiodynamic polarization measurements in standard 3.5 wt. % NaCl solution at room temperature. The results indicate that the benzene and HMDSO deposited films are suitable for protection of the aluminum substrate against corrosion. The changes in the processing parameters seem to have a strong influence on the film protective ability. Surface roughness of films deposited on aluminum alloy substrate was investigated using scanning electron microscopy (SEM). The SEM images indicate that the surface roughness of benzene deposited films increase with decreasing the benzene ratio. SEM images of benzene and HMDSO deposited films indicate that the surface roughness decreases with increasing r.f. power. Studying the above parameters indicate that the films produced are suitable for specific practical applications.

Keywords: Plasma polymerization, potentiodynamic test, Contact angle.

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Authors: Jagmohan Datt, Uma Batra

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Present investigations involve a systematic study on the machinability of austempered ductile irons (ADI) developed from four commercially viable ductile irons alloyed with different contents of 0, 0.1, 0.3 and 0.6 wt.% of Ni. The influence of Ni content, amount of retained austenite and hardness of ADI on machining behavior has been conducted systematically. Austempering heat treatment was carried out for 120 minutes at four temperatures- 270oC, 320oC, 370oC or 420oC, after austenitization at 900oC for 120 min. Milling tests were performed and machinability index, cutting forces and surface roughness measurements were used to evaluate the machinability. Higher cutting forces, lower machinability index and the poorer surface roughness of the samples austempered at lower temperatures indicated that austempering at higher temperatures resulted in better machinability. The machinability of samples austempered at 420oC, which contained higher fractions of retained austenite, was superior to that of samples austempered at lower temperatures, indicating that hardness is an important factor in assessing machinability in addition to high carbon austenite content. The ADI with 0.6% Ni, austempered at 420°C for 120 minutes, demonstrated best machinability.

Keywords: Austempering, machinability, machining index, cutting force, surface finish.

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Authors: R. Manimaran

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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: Sarabjeet Singh Sidhu, Ajay Batish, Sanjeev Kumar

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This paper reports the optimal process conditions for machining of three different types of MMC’s 65vol%SiC/A356.2; 10vol%SiC-5vol%quartz/Al and 30vol%SiC/A359 using PMEDM process. MRR, TWR, SR and surface integrity were evaluated after each trial and contributing process parameters were identified. The four responses were then collectively optimized using TOPSIS and optimal process conditions were identified for each type of MMC. The density of reinforced particles shields the matrix material from spark energy hence the high MRR and SR was observed with lowest reinforced particle. TWR was highest with Cu-Gr electrode due to disintegration of the weakly bonded particles in the composite electrode. Each workpiece was examined for surface integrity and ranked as per severity of surface defects observed and their rankings were used for arriving at the most optimal process settings for each workpiece. 

Keywords: Metal matrix composites (MMCs), Metal removal rate (MRR), Surface roughness (SR), Surface integrity (SI), Tool wear rate (TWR), Technique for order preference by similarity to ideal solution (TOPSIS).

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Authors: Ali Khaleel Kareem, Shian Gao, Ahmed Qasim Ahmed

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A numerical investigation of unsteady mixed convection heat transfer in a 3D moving top wall enclosure, which has a central rotating cylinder and uses either artificial roughness on the bottom hot plate or smooth bottom hot plate to study the heat transfer enhancement, is completed for fixed circular cylinder, and anticlockwise and clockwise rotational speeds, -1 ≤ Ω ≤ 1, at Reynolds number of 5000. The top lid-driven wall was cooled, while the other remaining walls that completed obstructed cubic were kept insulated and motionless. A standard k-ε model of Unsteady Reynolds-Averaged Navier-Stokes (URANS) method is involved to deal with turbulent flow. It has been clearly noted that artificial roughness can strongly control the thermal fields and fluid flow patterns. Ultimately, the heat transfer rate has been dramatically increased by involving artificial roughness on the heated bottom wall in the presence of rotating cylinder.

Keywords: Artificial roughness, Lid-driven cavity, Mixed convection heat transfer, Rotating cylinder, URANS method.

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Authors: Tadashi Watanabe, Jinya Katsuyama, Akihiro Mano

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The estimation of leak flow rates through narrow cracks in structures is of importance for nuclear reactor safety, since the leak flow could be detected before occurrence of loss-of-coolant accidents. The two-phase critical leak flow rates are calculated using the system analysis code, and two representative non-homogeneous critical flow models, Henry-Fauske model and Ransom-Trapp model, are compared. The pressure decrease and vapor generation in the crack, and the leak flow rates are found to be larger for the Henry-Fauske model. It is shown that the leak flow rates are not affected by the structural temperature, but affected largely by the roughness of crack surface.

Keywords: Crack, critical flow, leak, roughness.

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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: Gaurav D. Sonawane, Vikas G. Sargade

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The present investigation is a study of the effect of advanced Physical Vapor Deposition (PVD) coatings on cutting temperature residual stresses and surface roughness during Duplex Stainless Steel (DSS) 2205 turning. Austenite stabilizers like nickel, manganese, and molybdenum reduced the cost of DSS. Surface Integrity (SI) plays an important role in determining corrosion resistance and fatigue life. Resistance to various types of corrosion makes DSS suitable for applications with critical environments like Heat exchangers, Desalination plants, Seawater pipes and Marine components. However, lower thermal conductivity, poor chip control and non-uniform tool wear make DSS very difficult to machine. Cemented carbide tools (M grade) were used to turn DSS in a dry environment. AlTiN and AlTiCrN coatings were deposited using advanced PVD High Pulse Impulse Magnetron Sputtering (HiPIMS) technique. Experiments were conducted with cutting speed of 100 m/min, 140 m/min and 180 m/min. A constant feed and depth of cut of 0.18 mm/rev and 0.8 mm were used, respectively. AlTiCrN coated tools followed by AlTiN coated tools outperformed uncoated tools due to properties like lower thermal conductivity, higher adhesion strength and hardness. Residual stresses were found to be compressive for all the tools used for dry turning, increasing the fatigue life of the machined component. Higher cutting temperatures were observed for coated tools due to its lower thermal conductivity, which results in very less tool wear than uncoated tools. Surface roughness with uncoated tools was found to be three times higher than coated tools due to lower coefficient of friction of coating used.

Keywords: Cutting temperatures, DSS2205, dry turning, HiPIMS, surface integrity.

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Authors: I. Hosni, L. Bennaceur Farah, N. Saber, R Bennaceur

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Soil moisture content is a key variable in many environmental sciences. Even though it represents a small proportion of the liquid freshwater on Earth, it modulates interactions between the land surface and the atmosphere, thereby influencing climate and weather. Accurate modeling of the above processes depends on the ability to provide a proper spatial characterization of soil moisture. The measurement of soil moisture content allows assessment of soil water resources in the field of hydrology and agronomy. The second parameter in interaction with the radar signal is the geometric structure of the soil. Most traditional electromagnetic models consider natural surfaces as single scale zero mean stationary Gaussian random processes. Roughness behavior is characterized by statistical parameters like the Root Mean Square (RMS) height and the correlation length. Then, the main problem is that the agreement between experimental measurements and theoretical values is usually poor due to the large variability of the correlation function, and as a consequence, backscattering models have often failed to predict correctly backscattering. In this study, surfaces are considered as band-limited fractal random processes corresponding to a superposition of a finite number of one-dimensional Gaussian process each one having a spatial scale. Multiscale roughness is characterized by two parameters, the first one is proportional to the RMS height, and the other one is related to the fractal dimension. Soil moisture is related to the complex dielectric constant. This multiscale description has been adapted to two-dimensional profiles using the bi-dimensional wavelet transform and the Mallat algorithm to describe more correctly natural surfaces. We characterize the soil surfaces and sub-surfaces by a three layers geo-electrical model. The upper layer is described by its dielectric constant, thickness, a multiscale bi-dimensional surface roughness model by using the wavelet transform and the Mallat algorithm, and volume scattering parameters. The lower layer is divided into three fictive layers separated by an assumed plane interface. These three layers were modeled by an effective medium characterized by an apparent effective dielectric constant taking into account the presence of air pockets in the soil. We have adopted the 2D multiscale three layers small perturbations model including, firstly air pockets in the soil sub-structure, and then a vegetable canopy in the soil surface structure, that is to simulate the radar backscattering. A sensitivity analysis of backscattering coefficient dependence on multiscale roughness and new soil moisture has been performed. Later, we proposed to change the dielectric constant of the multilayer medium because it takes into account the different moisture values of each layer in the soil. A sensitivity analysis of the backscattering coefficient, including the air pockets in the volume structure with respect to the multiscale roughness parameters and the apparent dielectric constant, was carried out. Finally, we proposed to study the behavior of the backscattering coefficient of the radar on a soil having a vegetable layer in its surface structure.

Keywords: Multiscale, bi-dimensional, wavelets, SPM, backscattering, multilayer, air pockets, vegetable.

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Authors: M. Jalali Azizpour, H. Mohammadi majd

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In this paper, the wear of high speed steel hobs during hobbing has been studied. The wear mechanisms are strongly influenced by the choice of cutting speed. At moderate and high cutting speeds three major wear mechanisms were identified: abrasion, mild adhesive and severe adhesive. The microstructure and wear behavior of two high speed steel grades (M2 and ASP30) has been compared. In contrast, a variation in chemical composition or microstructure of HSS tool material generally did not change the dominant wear mechanism. However, the tool material properties determine the resistance against the operating wear mechanism and consequently the tool life. The metallographic analysis and wear measurement at the tip of hob teeth included scanning electron microscopy and stereoscope microscopy. Roughness profilometery is used for measuring the gear surface roughness.

Keywords: abrasion, adhesion, cutting speed, hobbing, wear mechanism

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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: Ahmed A. D. Sarhan, Hong Wan Ping, M. Sayuti

Abstract:

In this current era of competitive machinery productions, the industries are designed to place more emphasis on the product quality and reduction of cost whilst abiding by the pollution-preventing policy. In attempting to delve into the concerns, the industries are aware that the effectiveness of existing lubrication systems must be improved to achieve power-efficient and pollution-preventing machining processes. As such, this research is targeted to study on a plausible solution to the issue in grinding titanium alloy (Ti-6Al-4V) by using nanolubrication, as an alternative to flood grinding. The aim of this research is to evaluate the optimum condition of grinding force and surface roughness using MQL lubricating system to deliver nano-oil at different level of weight concentration of Silicon Dioxide (SiO₂) mixed normal mineral oil. Taguchi Design of Experiment (DoE) method is carried out using a standard Taguchi orthogonal array of L16(43) to find the optimized combination of weight concentration mixture of SiO₂, nozzle orientation and pressure of MQL. Surface roughness and grinding force are also analyzed using signal-to-noise(S/N) ratio to determine the best level of each factor that are tested. Consequently, the best combination of parameters is tested for a period of time and the results are compared with conventional grinding method of dry and flood condition. The results show a positive performance of MQL nanolubrication.  

Keywords: Grinding, MQL, precision grinding, Taguchi optimization, titanium alloy.

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Authors: M. Amrita, R. R. Srikant, A. V. Sita Rama Raju

Abstract:

Water miscible cutting fluids are conventionally used to lubricate and cool the machining zone. But issues related to health hazards, maintenance and disposal costs have limited their usage, leading to application of Minimum Quantity Lubrication (MQL). To increase the effectiveness of MQL, nanocutting fluids are proposed. In the present work, water miscible nanographite cutting fluids of varying concentration are applied at cutting zone by two systems A and B. System A utilizes high pressure air and supplies cutting fluid at a flow rate of 1ml/min. System B uses low pressure air and supplies cutting fluid at a flow rate of 5ml/min. Their performance in machining is evaluated by measuring cutting temperatures, tool wear, cutting forces and surface roughness and compared with dry machining and flood machining. Application of nanocutting fluid using both systems showed better performance than dry machining. Cutting temperatures and cutting forces obtained by both techniques are more than flood machining. But tool wear and surface roughness showed improvement compared to flood machining. Economic analysis has been carried out in all the cases to decide the applicability of the techniques.

Keywords: Economic analysis, Machining, Minimum Quantity lubrication, nanofluid.

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Authors: D. Mirauda, M. Greco, A. Volpe Plantamura

Abstract:

The necessity of updating the numerical models inputs, because of geometrical and resistive variations in rivers subject to solid transport phenomena, requires detailed control and monitoring activities. The human employment and financial resources of these activities moves the research towards the development of expeditive methodologies, able to evaluate the outflows through the measurement of more easily acquirable sizes. Recent studies highlighted the dependence of the entropic parameter on the kinematical and geometrical flow conditions. They showed a meaningful variability according to the section shape, dimension and slope. Such dependences, even if not yet well defined, could reduce the difficulties during the field activities, and also the data elaboration time. On the basis of such evidences, the relationships between the entropic parameter and the geometrical and resistive sizes, obtained through a large and detailed laboratory experience on steady free surface flows in conditions of macro and intermediate homogeneous roughness, are analyzed and discussed.

Keywords: Froude number, entropic parameter, roughness, water discharge.

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