Search results for: Surface defect.

Authors: Yusuf S. Dambatta, Ahmed A. D. Sarhan

Abstract:

Fused deposition modelling (FDM) is one of the most prominent rapid prototyping (RP) technologies which is being used to efficiently fabricate CAD 3D geometric models. However, the process is coupled with many drawbacks, of which the surface quality of the manufactured RP parts is among. Hence, studies relating to improving the surface roughness have been a key issue in the field of RP research. In this work, a technique of modelling the surface roughness in FDM is presented. Using experimentally measured surface roughness response of the FDM parts, an ANFIS prediction model was developed to obtain the surface roughness in the FDM parts using the main critical process parameters that affects the surface quality. The ANFIS model was validated and compared with experimental test results.

Keywords: Surface roughness, fused deposition modelling, adaptive neuro fuzzy inference system, ANFIS, orientation.

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Authors: C. Agrawal, R. Kumar, A. Gupta, B. Chatterjee

Abstract:

An experimental investigation has been carried out to study the cooling of a hot horizontal Stainless Steel surface of 3 mm thickness, which has 800±10 C initial temperature. A round water jet of 22 ± 1 oC temperature was injected over the hot surface through straight tube type nozzles of 2.5- 4.8 mm diameter and 250 mm length. The experiments were performed for the jet exit to target surface spacing of 4 times of jet diameter and jet Reynolds number of 5000 -24000. The effect of change in jet Reynolds number on the surface quenching has been investigated form the stagnation point to 16 mm spatial location.  

Keywords: Hot-Surface, Jet Impingement, Quenching, Stagnation Point.

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Authors: M.A. Kamely, S.M. Kamil, C.W. Chong

Abstract:

A mathematical model of the surface roughness has been developed by using response surface methodology (RSM) in grinding of AISI D2 cold work tool steels. Analysis of variance (ANOVA) was used to check the validity of the model. Low and high value for work speed and feed rate are decided from design of experiment. The influences of all machining parameters on surface roughness have been analyzed based on the developed mathematical model. The developed prediction equation shows that both the feed rate and work speed are the most important factor that influences the surface roughness. The surface roughness was found to be the lowers with the used of low feed rate and low work speed. Accuracy of the best model was proved with the testing data.

Keywords: Mathematical Modeling, Response surfacemethodology, Surface roughness, Cylindrical Grinding.

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Authors: T. Zlámal, J. Petrů, M. Pagáč, P. Krajkovič

Abstract:

For the required function of components with the thermal spray coating, it is necessary to perform additional machining of the coated surface. The paper deals with assessing the surface integrity of Metco 2042, a plasma sprayed coating, after its machining. The selected plasma sprayed coating serves as an abradable sealing coating in a jet engine. Therefore, the spray and its surface must meet high quality and functional requirements. Plasma sprayed coatings are characterized by lamellar structure, which requires a special approach to their machining. Therefore, the experimental part involves the set-up of special cutting tools and cutting parameters under which the applied coating was machined. For the assessment of suitably set machining parameters, selected parameters of surface integrity were measured and evaluated during the experiment. To determine the size of surface irregularities and the effect of the selected machining technology on the sprayed coating surface, the surface roughness parameters Ra and Rz were measured. Furthermore, the measurement of sprayed coating surface hardness by the HR 15 Y method before and after machining process was used to determine the surface strengthening. The changes of strengthening were detected after the machining. The impact of chosen cutting parameters on the surface roughness after the machining was not proven.

Keywords: Machining, plasma sprayed coating, surface integrity, strengthening.

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Authors: P. S. Dabeer, G. K. Purohit

Abstract:

Burnishing is a method of finishing and hardening machined parts by plastic deformation of the surface. Experimental work based on central composite second order rotatable design has been carried out on a lathe machine to establish the effects of ball burnishing parameters on the surface roughness of brass material. Analysis of the results by the analysis of variance technique and the F-test show that the parameters considered, have significant effects on the surface roughness.

Keywords: Ball burnishing, Response surface Methodology.

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Authors: Yusuke Uchiyama, Hidetoshi Konno

Abstract:

We have investigated statistical properties of the defect turbulence in 1D CGLE wherein many body interaction is involved between local depressing wave (LDW) and local standing wave (LSW). It is shown that the counting number fluctuation of LDW is subject to the sub-Poisson statistics (SUBP). The physical origin of the SUBP can be ascribed to pair extinction of LDWs based on the master equation approach. It is also shown that the probability density function (pdf) of inter-LDW distance can be identified by the hyper gamma distribution. Assuming a superstatistics of the exponential distribution (Poisson configuration), a plausible explanation is given. It is shown further that the pdf of amplitude of LDW has a fattail. The underlying mechanism of its fluctuation is examined by introducing a generalized fractional Poisson configuration.

Keywords: sub-Poisson statistics, hyper gamma distribution, fractional Poisson configuration.

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Authors: Amoljit S. Gill, Sanjeev Kumar

Abstract:

In this study, Electrical Discharge Machining (EDM) is used to modify the surface of high carbon steel En31 with the help of tool electrode (Copper-Chromium-Nickel) manufactured by powder metallurgy (PM) process. The effect of EDM on surface roughness during surface alloying is studied. Taguchi’s Design of experiment (DOE) and L18 orthogonal array is used to find the best level of input parameters in order to achieve high surface finish. Six input parameters are considered and their percentage contribution towards surface roughness is investigated by analysis of variances (ANOVA). Experimental results show that an hard alloyed surface (1.21% carbon, 2.14% chromium and 1.38% nickel) with surface roughness of 3.19µm can be generated using EDM with PM tool. Additionally, techniques like Scanning Electron Microscope (SEM) and Energy Dispersive Spectroscopy (EDS) are used to analyze the machined surface and EDMed layer composition, respectively. The increase in machined surface micro-hardness (101%) may be related to the formation of carbides containing chromium.

Keywords: Electrical Discharge Machining, Surface Roughness, Powder metallurgy compact tools, Taguchi DOE technique.

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Authors: Muhammed Çetin, Yılmaz Tunçer, Nejat Ekmekçi

Abstract:

In this paper, the translation surfaces in 3-dimensional Euclidean space generated by two space curves have been investigated. It has been indicated that Scherk surface is not only minimal translation surface.

Keywords: Minimal surface, Surface of Scherk, Translationsurface

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Authors: O. Takakuwa, Y. Mano, H. Soyama

Abstract:

This paper reveals the interaction between hydrogen and surface stress in austenitic stainless steel by X-ray diffraction stress measurement and thermal desorption analysis before and after being charged with hydrogen. The surface residual stress was varied by surface finishing using several disc polishing agents. The obtained results show that the residual stress near surface had a significant effect on hydrogen absorption behavior, that is, tensile residual stress promoted the hydrogen absorption and compressive one did opposite. Also, hydrogen induced equi-biaxial stress and this stress has a linear correlation with hydrogen content.

Keywords: Hydrogen embrittlement, Residual stress, Surface finishing, Stainless steel.

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Authors: Khawtar Hasan Ahmed, Sasha Omanovic

Abstract:

Polarization modulation infrared reflection absorption spectroscopy (PM-IRRAS) in combination with electrochemistry, was employed to study the influence of surface charge (potential) on the kinetics of bovine serum albumin (BSA) adsorption on a biomedical-grade 316LVM stainless steel surface is discussed. The BSA adsorption kinetics was found to greatly depend on the surface potential. With an increase in surface potential towards more negative values, both the BSA initial adsorption rate and the equilibrium (saturated) surface concentration also increased. Both effects were explained on the basis of replacement of well-ordered water molecules at the 316LVM / solution interface, i.e. by the increase in entropy of the system.

Keywords: adsorption, biomedical grade stainless steel, bovine serum albumin (BSA), electrode surface potential / charge, kinetics, PM-IRRAS, protein/surface interactions

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

Abstract:

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

Keywords: Burnishing process, Al-Mg-Graphite composites, Surface hardness, Surface roughness.

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Authors: Busra Balli, Tuncay Dikici, Mustafa Toparli

Abstract:

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

Keywords: Dental implant, etching, surface modifications, surface morphology, surface roughness.

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Authors: P. R. Prabhu, S. M. Kulkarni, S. S. Sharma

Abstract:

Deep cold rolling (DCR) is a cold working process, which easily produces a smooth and work-hardened surface by plastic deformation of surface irregularities. In the present study, the influence of main deep cold rolling process parameters on the surface roughness and the hardness of AISI 4140 steel were studied by using fractional factorial design of experiments. The assessment of the surface integrity aspects on work material was done, in terms of identifying the predominant factor amongst the selected parameters, their order of significance and setting the levels of the factors for minimizing surface roughness and/or maximizing surface hardness. It was found that the ball diameter, rolling force, initial surface roughness and number of tool passes are the most pronounced parameters, which have great effects on the work piece-s surface during the deep cold rolling process. A simple, inexpensive and newly developed DCR tool, with interchangeable collet for using different ball diameters, was used throughout the experimental work presented in this paper.

Keywords: Deep cold rolling, design of experiments, surface hardness, surface roughness

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Authors: Weifeng Wang, Xianwei Zeng, Jianping Ding

Abstract:

When the characteristic length of an elastic solid is down to the nanometer level, its deformation behavior becomes size dependent. Surface energy /surface stress have recently been applied to explain such dependency. In this paper, the effect of strain-independent surface stress on the deformation of an isotropic elastic solid containing a nanosized elliptical hole is studied by the finite element method. Two loading cases are considered, in the first case, hoop stress along the rim of the elliptical hole induced by pure surface stress is studied, in the second case, hoop stress around the elliptical opening under combined remote tension and surface stress is investigated. It has been shown that positive surface stress induces compressive hoop stress along the hole, and negative surface stress has opposite effect, maximum hoop stress occurs near the major semi-axes of the ellipse. Under combined loading of remote tension and surface stress, stress concentration around the hole can be either intensified or weakened depending on the sign of the surface stress.

Keywords: Surface stress, finite element method, stress concentration, nanosized elliptical hole

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Authors: L. Tao, T. J. Sun, Z. H. Li

Abstract:

The knowledge base of welding defect recognition is essentially incomplete. This characteristic determines that the recognition results do not reflect the actual situation. It also has a further influence on the classification of welding quality. This paper is concerned with the study of a rough set based method to reduce the influence and improve the classification accuracy. At first, a rough set model of welding quality intelligent classification has been built. Both condition and decision attributes have been specified. Later on, groups of the representative multiple compound defects have been chosen from the defect library and then classified correctly to form the decision table. Finally, the redundant information of the decision table has been reducted and the optimal decision rules have been reached. By this method, we are able to reclassify the misclassified defects to the right quality level. Compared with the ordinary ones, this method has higher accuracy and better robustness.

Keywords: intelligent decision, rough set, welding defects, welding quality level

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Authors: Zeinab Ghasemi, S. Amirhassan Monadjemi, Abbas Vafaei

Abstract:

This paper presents a comparative analysis of a new unsupervised PCA-based technique for steel plates texture segmentation towards defect detection. The proposed scheme called Variance Based Component Analysis or VBCA employs PCA for feature extraction, applies a feature reduction algorithm based on variance of eigenpictures and classifies the pixels as defective and normal. While the classic PCA uses a clusterer like Kmeans for pixel clustering, VBCA employs thresholding and some post processing operations to label pixels as defective and normal. The experimental results show that proposed algorithm called VBCA is 12.46% more accurate and 78.85% faster than the classic PCA.

Keywords: Principal Component Analysis; Variance Based Component Analysis; Defect Detection; Texture Segmentation.

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Authors: Pawan S. Nagda, Purnank S. Bhatt, Mit K. Shah

Abstract:

Earing defect in drawing process is highly undesirable not only because it adds on an additional trimming operation but also because the uneven material flow demands extra care. The objective of this work is to study the earing problem in the Deep Drawing of circular cup and to optimize the blank shape to reduce the earing. A finite element model is developed for 3-D numerical simulation of cup forming process in ABAQUS. Extra-deep-drawing (EDD) steel sheet has been used for simulation. Properties and tool design parameters were used as input for simulation. Earing was observed in the simulated cup and it was measured at various angles with respect to rolling direction. To reduce the earing defect initial blank shape was modified with the help of anisotropy coefficient. Modified blanks showed notable reduction in earing.

Keywords: Finite element simulation, deep drawing, earing, anisotropy.

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Authors: M.Ghazvini, S. A. Monadjemi, N. Movahhedinia, K. Jamshidi

Abstract:

In this article, a method has been offered to classify normal and defective tiles using wavelet transform and artificial neural networks. The proposed algorithm calculates max and min medians as well as the standard deviation and average of detail images obtained from wavelet filters, then comes by feature vectors and attempts to classify the given tile using a Perceptron neural network with a single hidden layer. In this study along with the proposal of using median of optimum points as the basic feature and its comparison with the rest of the statistical features in the wavelet field, the relational advantages of Haar wavelet is investigated. This method has been experimented on a number of various tile designs and in average, it has been valid for over 90% of the cases. Amongst the other advantages, high speed and low calculating load are prominent.

Keywords: Defect detection, tile and ceramic quality inspection, wavelet transform, classification, neural networks, statistical features.

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Authors: Keshav Pujeri, Pranesh Jain, Krutibas Panda

Abstract:

Significant changes in oil and gas drilling have emphasized the need to verify the integrity and reliability of drill stem components. Defects are inevitable in cast components, regardless of application; but if these defects go undetected, any severe defect could cause down-hole failure. One such defect is shrinkage porosity. Castings with lower level shrinkage porosity (CB levels 1 and 2) have scattered pores and do not occupy large volumes; so pressure testing and helium leak testing (HLT) are sufficient for qualifying the castings. However, castings with shrinkage porosity of CB level 3 and higher, behave erratically under pressure testing and HLT making these techniques insufficient for evaluating the castings- integrity. This paper presents a case study to highlight how the radiography technique is much more effective than pressure testing and HLT.

Keywords: Casting Defects, Interconnects, Leak Check, Pressure Test, Radiography.

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Authors: Mohamed El Morsy, Gabriela Achtenová

Abstract:

Research on damage of gears and gear pairs using vibration signals remains very attractive, because vibration signals from a gear pair are complex in nature and not easy to interpret. Predicting gear pair defects by analyzing changes in vibration signal of gears pairs in operation is a very reliable method. Therefore, a suitable vibration signal processing technique is necessary to extract defect information generally obscured by the noise from dynamic factors of other gear pairs.This article presents the value of cepstrum analysis in vehicle gearbox fault diagnosis. Cepstrum represents the overall power content of a whole family of harmonics and sidebands when more than one family of sidebands is present at the same time. The concept for the measurement and analysis involved in using the technique are briefly outlined. Cepstrum analysis is used for detection of an artificial pitting defect in a vehicle gearbox loaded with different speeds and torques. The test stand is equipped with three dynamometers; the input dynamometer serves asthe internal combustion engine, the output dynamometers introduce the load on the flanges of the output joint shafts. The pitting defect is manufactured on the tooth side of a gear of the fifth speed on the secondary shaft. Also, a method for fault diagnosis of gear faults is presented based on order Cepstrum. The procedure is illustrated with the experimental vibration data of the vehicle gearbox. The results show the effectiveness of Cepstrum analysis in detection and diagnosis of the gear condition.

Keywords: Cepstrum analysis, fault diagnosis, gearbox.

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Authors: Shiang-Cheng Jeng, Horng-Shing Chiou

Abstract:

A first intermediate roll of Sendzirmir mills was failure by surface spalling during operation. After analyzing by visual, stereo microscope, optical microscope, scanning electron microscope, glow-discharged spectrometer and hardness test, respectively, the results show that some voids and cracks existed on the contact surface as well as subsurface. Further examination verified inadequate hardness and inclusions were responsible for the failure of surface spalling.

Keywords: Sendzirmir mills; surface spalling; fatigue failure;inclusion; contact stress

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

Abstract:

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

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

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Authors: Ssu-Han Chen, Der-Baau Perng

Abstract:

Molding process in IC manufacturing secures chips against the harms done by hot, moisture or other external forces. While a chip was being molded,defects like cracks, dilapidation, or voids may be embedding on the molding surface. The molding surfaces the study poises to treat and the ones on the market, though, differ in the surface where texture similar to defects is everywhere. Manual inspection usually passes over low-contrast cracks or voids; hence an automatic optical inspection system for molding surface is necessary. The proposed system is consisted of a CCD, a coaxial light, a back light as well as a motion control unit. Based on the property of statistical textures of the molding surface, a series of digital image processing and classification procedure is carried out. After training of the parameter associated with above algorithm, result of the experiment suggests that the accuracy rate is up to 93.75%, contributing to the inspection quality of IC molding surface.

Keywords: Molding surface, machine vision, statistical texture, discrete Fourier transformation.

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Authors: M. Yoshikawa, N. Tsuji, T. Yabuuchi, Y Shimomura, H. Kakigi, H. Hayashi, H. Ohgushi

Abstract:

A scaffold is necessary for tooth regeneration because of its three-dimensional geometry. For restoration of defect, it is necessary for the scaffold to be prepared in the shape of the defect. Sponges made from polyvinyl alcohol with formalin cross-linking (PVF sponge) have been used for scaffolds for bone formation in vivo. To induce osteogenesis within the sponge, methods of growing rat bone marrow cells (rBMCs) among the fiber structures in the sponge might be considered. Storage of rBMCs among the fibers in the sponge coated with dextran (10 kDa) was tried. After seeding of rBMCs to PVF sponge immersed in dextran solution at 2 g/dl concentration, osteogenesis was recognized in subcutaneously implanted PVF sponge as a scaffold in vivo. The level of osteocalcin was 25.28±5.71 ng/scaffold and that of Ca was 129.20±19.69 µg/scaffold. These values were significantly higher than those in sponges without dextran coating (p<0.01). Osteogenesis was induced in many spaces in the inner structure of the sponge with dextran coated fibers.

Keywords: Dextran, Polyvinyl formal sponge, Osteogenesis, Scaffold.

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Authors: Saleh Abu Dabous, Khaled Hamad, Rami Al-Ruzouq

Abstract:

Bridge condition assessment and rating provide essential information needed for bridge management. This paper reviews bridge inspection and condition rating practices and introduces a defect-based urgency index. The index is estimated at the element-level based on the extent and severity of the different defects typical to the bridge element. The urgency index approach has the following advantages: (1) It facilitates judgment submission, i.e. instead of rating the bridge element with a specific linguistic overall expression (which can be subjective and used differently by different people), the approach is based on assessing the defects; (2) It captures multiple defects that can be present within a deteriorated element; and (3) It reflects how critical the element is through quantifying critical defects and their severity. The approach can be further developed and validated. It is expected to be useful for practical purposes as an early-warning system for critical bridge elements.

Keywords: Condition rating, deterioration, inspection, maintenance.

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Authors: Punit Kumar, Niraj Kumar

Abstract:

The influence of transverse surface roughness on EHL characteristics has been investigated numerically using an extensive set of full EHL line contact simulations for shear-thinning lubricants under pure sliding condition. The shear-thinning behavior of lubricant is modeled using Carreau viscosity equation along with Doolittle-Tait equation for lubricant compressibility. The surface roughness is assumed to be sinusoidal and it is present on the stationary surface. It is found that surface roughness causes sharp pressure peaks along with reduction in central and minimum film thickness. With increasing amplitude of surface roughness, the minimum film thickness decreases much more rapidly as compared to the central film thickness.

Keywords: EHL, Carreau, Shear-thinning, Surface Roughness, Amplitude, Wavelength.

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Authors: Somkiat Tangjitsitcharoen, Siripong Damrongthaveesak

Abstract:

This paper presents an advance in monitoring and process control of surface roughness in CNC machine for the turning and milling processes. An integration of the in-process monitoring and process control of the surface roughness is proposed and developed during the machining process by using the cutting force ratio. The previously developed surface roughness models for turning and milling processes of the author are adopted to predict the inprocess surface roughness, which consist of the cutting speed, the feed rate, the tool nose radius, the depth of cut, the rake angle, and the cutting force ratio. The cutting force ratios obtained from the turning and the milling are utilized to estimate the in-process surface roughness. The dynamometers are installed on the tool turret of CNC turning machine and the table of 5-axis machining center to monitor the cutting forces. The in-process control of the surface roughness has been developed and proposed to control the predicted surface roughness. It has been proved by the cutting tests that the proposed integration system of the in-process monitoring and the process control can be used to check the surface roughness during the cutting by utilizing the cutting force ratio.

Keywords: Turning, milling, monitoring, surface roughness, cutting force ratio.

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Authors: Zhen-Hui Hu, Jyh-Shong Ju, Ming-Hwei Perng

Abstract:

This paper presents a useful sub-pixel image registration method using line segments and a sub-pixel edge detector. In this approach, straight line segments are first extracted from gray images at the pixel level before applying the sub-pixel edge detector. Next, all sub-pixel line edges are mapped onto the orientation-distance parameter space to solve for line correspondence between images. Finally, the registration parameters with sub-pixel accuracy are analytically solved via two linear least-square problems. The present approach can be applied to various fields where fast registration with sub-pixel accuracy is required. To illustrate, the present approach is applied to the inspection of printed circuits on a flat panel. Numerical example shows that the present approach is effective and accurate when target images contain a sufficient number of line segments, which is true in many industrial problems.

Keywords: Defect detection, Image registration, Straight line segment, Sub-pixel.

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Authors: Smriti H. Bhandari, S. M. Deshpande

Abstract:

Surface metrology with image processing is a challenging task having wide applications in industry. Surface roughness can be evaluated using texture classification approach. Important aspect here is appropriate selection of features that characterize the surface. We propose an effective combination of features for multi-scale and multi-directional analysis of engineering surfaces. The features include standard deviation, kurtosis and the Canny edge detector. We apply the method by analyzing the surfaces with Discrete Wavelet Transform (DWT) and Dual-Tree Complex Wavelet Transform (DT-CWT). We used Canberra distance metric for similarity comparison between the surface classes. Our database includes the surface textures manufactured by three machining processes namely Milling, Casting and Shaping. The comparative study shows that DT-CWT outperforms DWT giving correct classification performance of 91.27% with Canberra distance metric.

Keywords: Dual-tree complex wavelet transform, surface metrology, surface roughness, texture classification.

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Authors: Yousef Amer, Mehdi Moayyedian, Zeinab Hajiabolhasani, Lida Moayyedian

Abstract:

Moulded parts contribute to more than 70% of components in products. However, common defects particularly in plastic injection moulding exist such as: warpage, shrinkage, sink marks, and weld lines. In this paper Taguchi experimental design methods are applied to reduce the warpage defect of thin plate Acrylonitrile Butadiene Styrene (ABS) and are demonstrated in two levels; namely, orthogonal arrays of Taguchi and the Analysis of Variance (ANOVA). Eight trials have been run in which the optimal parameters that can minimize the warpage defect in factorial experiment are obtained. The results obtained from ANOVA approach analysis with respect to those derived from MINITAB illustrate the most significant factors which may cause warpage in injection moulding process. Moreover, ANOVA approach in comparison with other approaches like S/N ratio is more accurate and with the interaction of factors it is possible to achieve higher and the better outcomes.

Keywords: Analysis of variance, ANOVA, plastic injection mould, Taguchi methods, Warpage.

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