Search results for: material roughness.

Authors: Jean François Chatelain, Imed Zaghbani, Joseph Monier

Abstract:

The machining of Carbon Fiber Reinforced Plastics has come to constitute a significant challenge for many fields of industry. The resulting surface finish of machined parts is of primary concern for several reasons, including contact quality and impact on the assembly. Therefore, the characterization and prediction of roughness based on machining parameters are crucial for costeffective operations. In this study, a PCD tool comprised of two straight flutes was used to trim 32-ply carbon fiber laminates in a bid to analyze the effects of the feed rate and the cutting speed on the surface roughness. The results show that while the speed has but a slight impact on the surface finish, the feed rate for its part affects it strongly. A detailed study was also conducted on the effect of fiber orientation on surface roughness, for quasi-isotropic laminates used in aerospace. The resulting roughness profiles for the four-ply orientation lay-up were compared, and it was found that fiber angle is a critical parameter relating to surface roughness. One of the four orientations studied led to very poor surface finishes, and characteristic roughness profiles were identified and found to only relate to the ply orientations of multilayer carbon fiber laminates.

Keywords: Roughness, Detouring, Composites, Aerospace

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

Abstract:

The effect of upstream surface roughness over a smooth forward facing step in an open channel was investigated using a particle image velocimetry technique. Three different upstream surface topographies consisting of hydraulically smooth wall, sandpaper 36 grit and sand grains were examined. Besides the wall roughness conditions, all other upstream flow characteristics were kept constant. It was also observed that upstream roughness decreased the approach velocity by 2% and 10% but increased the turbulence intensity by 14% and 35% at the wall-normal distance corresponding to the top plane of the step compared to smooth upstream. The results showed that roughness decreased the reattachment lengths by 14% and 30% compared to smooth upstream. Although the magnitudes of maximum positive and negative Reynolds shear stress in separated and reattached region were 0.02Ue for all the cases, the physical size of both the maximum and minimum contour levels were decreased by increasing upstream roughness.

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

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Authors: Manish Pal, Rumi Sutradhar

Abstract:

Pavement surface unevenness plays a pivotal role on roughness index of road which affects on riding comfort ability. Comfort ability refers to the degree of protection offered to vehicle occupants from uneven elements in the road surface. So, it is preferable to have a lower roughness index value for a better riding quality of road users. Roughness is generally defined as an expression of irregularities in the pavement surface which can be measured using different equipments like MERLIN, Bump integrator, Profilometer etc. Among them Bump Integrator is quite simple and less time consuming in case of long road sections. A case study is conducted on low volume roads in West District in Tripura to determine roughness index (RI) using Bump Integrator at the standard speed of 32 km/h. But it becomes too tough to maintain the requisite standard speed throughout the road section. The speed of Bump Integrator (BI) has to lower or higher in some distinctive situations. So, it becomes necessary to convert these roughness index values of other speeds to the standard speed of 32 km/h. This paper highlights on that roughness index conversional model. Using SPSS (Statistical Package of Social Sciences) software a generalized equation is derived among the RI value at standard speed of 32 km/h and RI value at other speed conditions.

Keywords: Bump Integrator, Pavement Distresses, Roughness Index, SPSS.

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Authors: Naveen Beri, S. Maheshwari, C. Sharma, Anil Kumar

Abstract:

In this paper an attempt has been made to correlate the usefulness of electrodes made through powder metallurgy (PM) in comparison with conventional copper electrode during electric discharge machining. Experimental results are presented on electric discharge machining of AISI D2 steel in kerosene with copper tungsten (30% Cu and 70% W) tool electrode made through powder metallurgy (PM) technique and Cu electrode. An L18 (21 37) orthogonal array of Taguchi methodology was used to identify the effect of process input factors (viz. current, duty cycle and flushing pressure) on the output factors {viz. material removal rate (MRR) and surface roughness (SR)}. It was found that CuW electrode (made through PM) gives high surface finish where as the Cu electrode is better for higher material removal rate.

Keywords: Electrical discharge machining (EDM), Powder Metallurgy (PM), Taguchi method, Material Removal Rate (MRR), Surface Roughness (SR).

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Authors: S. Karabulut, A. Güllü, A. Güldas, R. Gürbüz

Abstract:

This study investigates the effects of the lead angle and chip thickness variation on surface roughness during the machining of compacted graphite iron using ceramic cutting tools under dry cutting conditions. Analytical models were developed for predicting the surface roughness values of the specimens after the face milling process. Experimental data was collected and imported to the artificial neural network model. A multilayer perceptron model was used with the back propagation algorithm employing the input parameters of lead angle, cutting speed and feed rate in connection with chip thickness. Furthermore, analysis of variance was employed to determine the effects of the cutting parameters on surface roughness. Artificial neural network and regression analysis were used to predict surface roughness. The values thus predicted were compared with the collected experimental data, and the corresponding percentage error was computed. Analysis results revealed that the lead angle is the dominant factor affecting surface roughness. Experimental results indicated an improvement in the surface roughness value with decreasing lead angle value from 88° to 45°.

Keywords: CGI, milling, surface roughness, ANN, regression, modeling, analysis.

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Authors: Ab. Rashid M.F.F., Gan S.Y., Muhammad N.Y.

Abstract:

Surface roughness (Ra) is one of the most important requirements in machining process. In order to obtain better surface roughness, the proper setting of cutting parameters is crucial before the process take place. This research presents the development of mathematical model for surface roughness prediction before milling process in order to evaluate the fitness of machining parameters; spindle speed, feed rate and depth of cut. 84 samples were run in this study by using FANUC CNC Milling α-Τ14ιE. Those samples were randomly divided into two data sets- the training sets (m=60) and testing sets(m=24). ANOVA analysis showed that at least one of the population regression coefficients was not zero. Multiple Regression Method was used to determine the correlation between a criterion variable and a combination of predictor variables. It was established that the surface roughness is most influenced by the feed rate. By using Multiple Regression Method equation, the average percentage deviation of the testing set was 9.8% and 9.7% for training data set. This showed that the statistical model could predict the surface roughness with about 90.2% accuracy of the testing data set and 90.3% accuracy of the training data set.

Keywords: Surface roughness, regression analysis.

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Authors: M. Yousaf, S. Usman

Abstract:

Numerical studies were conducted using Lattice Boltzmann Method (LBM) to study the natural convection in a square cavity in the presence of roughness. An algorithm based on a single relaxation time Bhatnagar-Gross-Krook (BGK) model of Lattice Boltzmann Method (LBM) was developed. Roughness was introduced on both the hot and cold walls in the form of sinusoidal roughness elements. The study was conducted for a Newtonian fluid of Prandtl number (Pr) 1.0. The range of Ra number was explored from 10^3 to 10^6 in a laminar region. Thermal and hydrodynamic behavior of fluid was analyzed using a differentially heated square cavity with roughness elements present on both the hot and cold wall. Neumann boundary conditions were introduced on horizontal walls with vertical walls as isothermal. The roughness elements were at the same boundary condition as corresponding walls. Computational algorithm was validated against previous benchmark studies performed with different numerical methods, and a good agreement was found to exist. Results indicate that the maximum reduction in the average heat transfer was 16.66 percent at Ra number 10^5.

Keywords: Lattice Boltzmann Method Natural convection, Nusselt Number Rayleigh number, Roughness.

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Authors: Manop Vorasri, Komson Jirapattarasilp, Sittichai Kaewkuekool

Abstract:

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

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

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Authors: M. Hakak Khadem, M. Shams, S. Hossainpour

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A two dimensional numerical simulation has been performed for incompressible and compressible fluid flow through microchannels in slip flow regime. The Navier-Stokes equations have been solved in conjunction with Maxwell slip conditions for modeling flow field associated with slip flow regime. The wall roughness is simulated with triangular microelements distributed on wall surfaces to study the effects of roughness on fluid flow. Various Mach and Knudsen numbers are used to investigate the effects of rarefaction as well as compressibility. It is found that rarefaction has more significant effect on flow field in microchannels with higher relative roughness. It is also found that compressibility has more significant effects on Poiseuille number when relative roughness increases. In addition, similar to incompressible models the increase in average fRe is more significant at low Knudsen number flows but the increase of Poiseuille number duo to relative roughness is sharper for compressible models. The numerical results have also validated with some available theoretical and experimental relations and good agreements have been seen.

Keywords: Relative roughness, slip flow, Poiseuille number.

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Authors: M. Yousaf, S. Usman

Abstract:

The present study focused on the investigation of the effects of roughness elements on heat transfer during natural convection in a rectangular cavity using numerical technique. Roughness elements were introduced on the bottom hot wall with a normalized amplitude (A*/H) of 0.1. Thermal and hydrodynamic behaviors were studied using computational method based on Lattice Boltzmann method (LBM). Numerical studies were performed for a laminar flow in the range of Rayleigh number (Ra) from 103 to 106 for a rectangular cavity of aspect ratio (L/H) 2.0 with a fluid of Prandtl number (Pr) 1.0. The presence of the sinusoidal roughness elements caused a minimum to maximum decrease in the heat transfer as 7% to 17% respectively compared to smooth enclosure. The results are presented for mean Nusselt number (Nu), isotherms and streamlines.

Keywords: Natural convection, Rayleigh number, surface roughness, Nusselt number, Lattice Boltzmann Method.

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Authors: M. P. Neupane, T. S. N. Sankara Narayanan, J. E. Park, Y. K. Kim, I. S. Park, K. Y. Song, T. S. Bae, M. H. Lee

Abstract:

Titanium oxide films with different morphologies have for the first time been fabricated through hydrothermal reactions between a titanium substrate and iodine powder in water or ethanol. SEM revealed that iodine supported titanium (Ti-I2) surface shows different morphologies with variable treatment conditions. The mean surface roughness (Ra) was increased in the different groups. Use of surfactant has a role to increase the roughness of the film. The surface roughness was in the range of 0.15 μm-0.42 μm. Furthermore, the electrochemical examinations showed that the Ti-I2 surface fabricated in alcoholic medium has high corrosion resistance than in aqueous medium.

Keywords: Corrosion, Hydrothermal, Surface roughness, Titanium oxide.

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Authors: Gurinder Singh Brar, Sarbjeet Singh, Harry Garg

Abstract:

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: Varun

Abstract:

Solar energy is a good option among renewable energy resources due to its easy availability and abundance. The simplest and most efficient way to utilize solar energy is to convert it into thermal energy and this can be done with the help of solar collectors. The thermal performance of such collectors is poor due to less heat transfer from the collector surface to air. In this work, experimental investigations of single pass solar air heater having triangular duct and provided with roughness element on the underside of the absorber plate. V-shaped ribs are used for investigation having three different values of relative roughness pitch (p/e) ranges from 4- 16 for a fixed value of angle of attack (α), relative roughness height (e/Dh) and a relative gap distance (d/x) values are 60°, 0.044 and 0.60 respectively. Result shows that considerable augmentation in heat transfer has been obtained by providing roughness.

Keywords: Artificial roughness, Solar Air heater, Triangular duct, V-Shaped Ribs.

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Authors: T. Magrakvelidze, N. Bantsadze, N. Lekveishvili, Kh. Lomidze

Abstract:

The results of an experimental study of the process of convective and boiling heat transfer in the vessel with stirrer for smooth and rough ring-shaped pipes are presented. It is established that creation of two-dimensional artificial roughness on the heated surface causes the essential (~100%) intensification of convective heat transfer. In case of boiling the influence of roughness appears on the initial stage of boiling and in case of fully developed nucleate boiling there was no intensification of heat transfer. The similitude equation for calculating convective heat transfer coefficient, which generalizes well experimental data both for the smooth and the rough surfaces is proposed.

Keywords: boiling, heat transfer, roughness.

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Authors: S. Ghorbani, N. I. Polushin

Abstract:

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

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

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

Abstract:

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

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

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Authors: Weinian Wang, Joseph C. Chen

Abstract:

The objective of this research is to optimize the process of cutting cylindrical workpieces utilizing live tooling on a HAAS ST-20 lathe. Surface roughness (Ra) has been investigated as the indicator of quality characteristics for machining process. Aluminum alloy was used to conduct experiments due to its wide range usages in engineering structures and components where light weight or corrosion resistance is required. In this study, Taguchi methodology is utilized to determine the effects that each of the parameters has on surface roughness (Ra). A total of 18 experiments of each process were designed according to Taguchi’s L9 orthogonal array (OA) with four control factors at three levels of each and signal-to-noise ratios (S/N) were computed with Smaller the better equation for minimizing the system. The optimal parameters identified for the surface roughness of the turning operation utilizing live tooling were a feed rate of 3 inches/min(A3); a spindle speed of 1300 rpm(B3); a 2-flute titanium nitrite coated 3/8” endmill (C1); and a depth of cut of 0.025 inches (D2). The mean surface roughness of the confirmation runs in turning operation was 8.22 micro inches. The final results demonstrate that Taguchi methodology is a sufficient way of process improvement in turning process on surface roughness.

Keywords: Live tooling, surface roughness, Taguchi Parameter Design, CNC turning operation.

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Authors: M. Jalali Azizpour, H. Mohammadi majd

Abstract:

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: M.Davami, M.Zadshakoyan

Abstract:

Production of hard-to-cut materials with uncoated carbide cutting tools in turning, not only cause tool life reduction but also, impairs the product surface roughness. In this paper, influence of hot machining method were studied and presented in two cases. Case1-Workpiece surface roughness quality with constant cutting parameter and 300 ºC initial workpiece surface temperature. Case 2- Tool temperature variation when cutting with two speeds 78.5 (m/min) and 51 (m/min). The workpiece material and tool used in this study were AISI 1060 steel (45HRC) and uncoated carbide TNNM 120408-SP10(SANDVIK Coromant) respectively. A gas flam heating source was used to preheating of the workpiece surface up to 300 ºC, causing reduction of yield stress about 15%. Results obtained experimentally, show that the method used can considerably improved surface quality of the workpiece.

Keywords: Hard-to-cut material, Hot machining, Surfaceroughness, Tool Temperature

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Authors: G. Murugeswari, A. Suruliandi

Abstract:

This paper proposes a rotational invariant texture feature based on the roughness property of the image for psoriasis image analysis. In this work, we have applied this feature for image classification and segmentation. The fuzzy concept is employed to overcome the imprecision of roughness. Since the psoriasis lesion is modeled by a rough surface, the feature is extended for calculating the Psoriasis Area Severity Index value. For classification and segmentation, the Nearest Neighbor algorithm is applied. We have obtained promising results for identifying affected lesions by using the roughness index and severity level estimation.

Keywords: Fuzzy texture feature, psoriasis, roughness feature, skin disease.

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Authors: A. Watanapa, S. Torsakul

Abstract:

This study was aimed to explain the influence of surface roughness of the drawbead on non-symmetry deep drawing cold rolled steel sheet to improve the drawability of cold rolled steel sheet. The variables used in this study included semi-circle drawbead with 3 levels of surface roughness which are 6.127 mm Ra, 0.963 mm Ra and 0.152 mm Ra and cold rolled steel sheet according to 3 grades of the JIS standards which are SPCC, SPCE and SPCD with the thickness of 1.0 mm and the blankholder force which is 50% of the drawing force and the depth of 50 mm. According to the test results, when there was the increase in the surface roughness of drawbead, there would be the increase in deep drawing force, especially the SPCC cold rolled steel sheet. This is similar to the increase in the equivalent strain and the wall thickness distribution when the surface roughness of the drawbead increased. It could be concluded that the surface roughness of drawbead has an influence on deep drawing cold rolled steel sheet, especially the drawing force, the equivalent strain and the wall thickness distribution.

Keywords: Drawbead, Deep Drawing, Drawing Force, Equivalent Strain, Surface roughness

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Authors: Vineeth G. Kuriakose, Joseph C. Chen, Ye Li

Abstract:

The research follows a systematic approach to optimize the parameters for parts machined by turning and milling processes. The quality characteristic chosen is surface roughness since the surface finish plays an important role for parts that require surface contact. A tapered cylindrical surface is designed as a test specimen for the research. The material chosen for machining is aluminum alloy 6061 due to its wide variety of industrial and engineering applications. HAAS VF-2 TR computer numerical control (CNC) vertical machining center is used for milling and HAAS ST-20 CNC machine is used for turning in this research. Taguchi analysis is used to optimize the surface roughness of the machined parts. The L₉ Orthogonal Array is designed for four controllable factors with three different levels each, resulting in 18 experimental runs. Signal to Noise (S/N) Ratio is calculated for achieving the specific target value of 75 ± 15 µin. The controllable parameters chosen for turning process are feed rate, depth of cut, coolant flow and finish cut and for milling process are feed rate, spindle speed, step over and coolant flow. The uncontrollable factors are tool geometry for turning process and tool material for milling process. Hypothesis testing is conducted to study the significance of different uncontrollable factors on the surface roughnesses. The optimal parameter settings were identified from the Taguchi analysis and the process capability C_p and the process capability index C_pk were improved from 1.76 and 0.02 to 3.70 and 2.10 respectively for turning process and from 0.87 and 0.19 to 3.85 and 2.70 respectively for the milling process. The surface roughnesses were improved from 60.17 µin to 68.50 µin, reducing the defect rate from 52.39% to 0% for the turning process and from 93.18 µin to 79.49 µin, reducing the defect rate from 71.23% to 0% for the milling process. The purpose of this study is to efficiently utilize the Taguchi design analysis to improve the surface roughness.

Keywords: CNC milling, CNC turning, surface roughness, Taguchi analysis.

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Authors: Md. Anayet U. Patwari, Mohammad Ahsan Habib, Md. Tanzib Ehsan, Md Golam Ahnaf, Md. S. I. Chowdhury

Abstract:

Surface roughness is one of the key quality parameters of the finished product. During any machining operation, high temperatures are generated at the tool-chip interface impairing surface quality and dimensional accuracy of products. Cutting fluids are generally applied during machining to reduce temperature at the tool-chip interface. However, usages of cutting fluids give rise to problems such as waste disposal, pollution, high cost, and human health hazard. Researchers, now-a-days, are opting towards dry machining and other cooling techniques to minimize use of coolants during machining while keeping surface roughness of products within desirable limits. In this paper, a concept of using peltier cooling effects during aluminium milling operation has been presented and adopted with an aim to improve surface roughness of the machined surface. Experimental evidence shows that peltier cooling effect provides better surface roughness of the machined surface compared to dry machining.

Keywords: Aluminium, surface roughness, Peltier cooling effect, milling operation.

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Authors: R. Hosseini, A. Gholaminejad, H. Jahandar

Abstract:

The present paper is an experimental investigation of roughness effects on nucleate pool boiling of refrigerant R113 on horizontal circular copper surfaces. The copper samples were treated by different sand paper grit sizes to achieve different surface roughness. The average surface roughness of the four samples was 0.901, 0.735, 0.65, and 0.09, respectively. The experiments were performed in the heat flux range of 8 to 200kW/m2. The heat transfer coefficient was calculated by measuring wall superheat of the samples and the input heat flux. The results show significant improvement of heat transfer coefficient as the surface roughness is increased. It is found that the heat transfer coefficient of the sample with Ra=0.901 is 3.4, 10.5, and 38.5% higher in comparison with surfaces with Ra of 0.735, 0.65, and 0.09 at heat flux of 170 kW/m2. Moreover, the results are compared with literature data and the well known Cooper correlation.

Keywords: Nucleate Boiling, Pool Boiling, R113, SurfaceRoughness

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Authors: Pankaj Chandna, Dinesh Kumar

Abstract:

The present work analyses different parameters of end milling to minimize the surface roughness for AISI D2 steel. D2 Steel is generally used for stamping or forming dies, punches, forming rolls, knives, slitters, shear blades, tools, scrap choppers, tyre shredders etc. Surface roughness is one of the main indices that determines the quality of machined products and is influenced by various cutting parameters. In machining operations, achieving desired surface quality by optimization of machining parameters, is a challenging job. In case of mating components the surface roughness become more essential and is influenced by the cutting parameters, because, these quality structures are highly correlated and are expected to be influenced directly or indirectly by the direct effect of process parameters or their interactive effects (i.e. on process environment). In this work, the effects of selected process parameters on surface roughness and subsequent setting of parameters with the levels have been accomplished by Taguchi’s parameter design approach. The experiments have been performed as per the combination of levels of different process parameters suggested by L9 orthogonal array. Experimental investigation of the end milling of AISI D2 steel with carbide tool by varying feed, speed and depth of cut and the surface roughness has been measured using surface roughness tester. Analyses of variance have been performed for mean and signal-to-noise ratio to estimate the contribution of the different process parameters on the process.

Keywords: D2 Steel, Orthogonal Array, Optimization, Surface Roughness, Taguchi Methodology.

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Authors: M.H. Ahmad Fadzil, Esa Prakasa, Hurriyatul Fitriyah, Hermawan Nugroho, Azura Mohd Affandi, S.H. Hussein

Abstract:

Psoriasis is a widespread skin disease affecting up to 2% population with plaque psoriasis accounting to about 80%. It can be identified as a red lesion and for the higher severity the lesion is usually covered with rough scale. Psoriasis Area Severity Index (PASI) scoring is the gold standard method for measuring psoriasis severity. Scaliness is one of PASI parameter that needs to be quantified in PASI scoring. Surface roughness of lesion can be used as a scaliness feature, since existing scale on lesion surface makes the lesion rougher. The dermatologist usually assesses the severity through their tactile sense, therefore direct contact between doctor and patient is required. The problem is the doctor may not assess the lesion objectively. In this paper, a digital image analysis technique is developed to objectively determine the scaliness of the psoriasis lesion and provide the PASI scaliness score. Psoriasis lesion is modelled by a rough surface. The rough surface is created by superimposing a smooth average (curve) surface with a triangular waveform. For roughness determination, a polynomial surface fitting is used to estimate average surface followed by a subtraction between rough and average surface to give elevation surface (surface deviations). Roughness index is calculated by using average roughness equation to the height map matrix. The roughness algorithm has been tested to 444 lesion models. From roughness validation result, only 6 models can not be accepted (percentage error is greater than 10%). These errors occur due the scanned image quality. Roughness algorithm is validated for roughness measurement on abrasive papers at flat surface. The Pearson-s correlation coefficient of grade value (G) of abrasive paper and Ra is -0.9488, its shows there is a strong relation between G and Ra. The algorithm needs to be improved by surface filtering, especially to overcome a problem with noisy data.

Keywords: psoriasis, roughness algorithm, polynomial surfacefitting.

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Authors: Samir Khrais, Adel Mahammod Hassan , Amro Gazawi

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The aim of this research is to evaluate surface roughness and develop a multiple regression model for surface roughness as a function of cutting parameters during the turning of flame hardened medium carbon steel with TiN-Al2O3-TiCN coated inserts. An experimental plan of work and signal-to-noise ratio (S/N) were used to relate the influence of turning parameters to the workpiece surface finish utilizing Taguchi methodology. The effects of turning parameters were studied by using the analysis of variance (ANOVA) method. Evaluated parameters were feed, cutting speed, and depth of cut. It was found that the most significant interaction among the considered turning parameters was between depth of cut and feed. The average surface roughness (Ra) resulted by TiN-Al2O3- TiCN coated inserts was about 2.44 μm and minimum value was 0.74 μm. In addition, the regression model was able to predict values for surface roughness in comparison with experimental values within reasonable limit.

Keywords: Medium carbon steel, Prediction, Surface roughness, Taguchi method

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Authors: Rajaram Kr. Gupta, Bhupendra Kumar, T. V. K. Gupta, D. S. Ramteke

Abstract:

Machining of hard materials is a recent technology for direct production of work-pieces. The primary challenge in machining these materials is selection of cutting tool inserts which facilitates an extended tool life and high-precision machining of the component. These materials are widely for making precision parts for the aerospace industry. Nickel-based alloys are typically used in extreme environment applications where a combination of strength, corrosion resistance and oxidation resistance material characteristics are required. The present paper reports the theoretical and experimental investigations carried out to understand the influence of machining parameters on the response parameters. Considering the basic machining parameters (speed, feed and depth of cut) a study has been conducted to observe their influence on material removal rate, surface roughness, cutting forces and corresponding tool wear. Experiments are designed and conducted with the help of Central Composite Rotatable Design technique. The results reveals that for a given range of process parameters, material removal rate is favorable for higher depths of cut and low feed rate for cutting forces. Low feed rates and high values of rotational speeds are suitable for better finish and higher tool life.

Keywords: Speed, feed, depth of cut, roughness, cutting force, flank wear.

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Authors: Lenka Ocenasova, Bartosz Gapinski, Robert Cep, Linda Gregova, Branimir Barisic, Jana Novakova, Lenka Petrkovska

Abstract:

Today technological process makes possible surface control of producing parts which is needful for product quality guarantee. Geometrical structure of part surface includes form, proportion, accuracy to shape, accuracy to size, alignment and surface topography (roughness, waviness, etc.). All these parameters are dependence at technology, production machine parameters, material properties, but also at human, etc. Every parameters approves at total part accuracy, it is means at accuracy to shape. One of the most important accuracy to shape element is roundness. This paper will be deals by comparison of roughness deviations at coordination measuring machines and at special single purpose machines. Will describing measuring by discreet method (discontinuous) and scanning method (continuous) at coordination measuring machines and confrontation with reference method using at single purpose machines.

Keywords: Coordinating Measuring Machines (CMM), Measuring Strategy, Roughness Deviation, Accuracy.

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Authors: J. Hajnys, M. Pagac, J. Petru, P. Stefek, J. Mesicek, J. Kratochvil

Abstract:

The new progressive method of 3D metal printing SLM (Selective Laser Melting) is increasingly expanded into the normal operation. As a result, greater demands are placed on the surface quality of the parts produced in this way. The article deals with research of selected finishing methods (tumbling, face milling, sandblasting, shot peening and brushing) and their impact on the final surface roughness. The 20 x 20 x 7 mm produced specimens using SLM additive technology on the Renishaw AM400 were subjected to testing of these finishing methods by adjusting various parameters. Surface parameters of roughness Sa, Sz were chosen as the evaluation criteria and profile parameters Ra, Rz were used as additional measurements. Optical measurement of surface roughness was performed on Alicona Infinite Focus 5. An experiment conducted to optimize the surface roughness revealed, as expected, that the best roughness parameters were achieved through a face milling operation. Tumbling is particularly suitable for 3D printing components, as tumbling media are able to reach even complex shapes and, after changing to polishing bodies, achieve a high surface gloss. Surface quality after tumbling depends on the process time. Other methods with satisfactory results are shot peening and tumbling, which should be the focus of further research.

Keywords: Additive manufacturing, selective laser melting, surface roughness, stainless steel.

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