Search results for: surface crack

Authors: P. Selva, B. Lorrain, J. Alexis, A. Seror, A. Longuet, C. Mary, F. Denard

Abstract:

Over the past four decades, the fatigue behavior of nickel-based alloys has been widely studied. However, in recent years, significant advances in the fabrication process leading to grain size reduction have been made in order to improve fatigue properties of aircraft turbine discs. Indeed, a change in particle size affects the initiation mode of fatigue cracks as well as the fatigue life of the material. The present study aims to investigate the fatigue behavior of a newly developed nickel-based superalloy under biaxial-planar loading. Low Cycle Fatigue (LCF) tests are performed at different stress ratios so as to study the influence of the multiaxial stress state on the fatigue life of the material. Full-field displacement and strain measurements as well as crack initiation detection are obtained using Digital Image Correlation (DIC) techniques. The aim of this presentation is first to provide an in-depth description of both the experimental set-up and protocol: the multiaxial testing machine, the specific design of the cruciform specimen and performances of the DIC code are introduced. Second, results for sixteen specimens related to different load ratios are presented. Crack detection, strain amplitude and number of cycles to crack initiation vs. triaxial stress ratio for each loading case are given. Third, from fractographic investigations by scanning electron microscopy it is found that the mechanism of fatigue crack initiation does not depend on the triaxial stress ratio and that most fatigue cracks initiate from subsurface carbides.

Keywords: Cruciform specimen, multiaxial fatigue, Nickelbased superalloy.

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Authors: S. Imbin, S. Dullah, H. Asrah, P. S. Kumar, M. E. Rahman, M. A. Mannan

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Service life of existing reinforced concrete (RC) structures in coastal towns of Sabah has been affected very much. Concrete crack, spalling of concrete cover and reinforcement rusting of RC buildings are seen even within 5 years of construction in Sabah. Hence, in this study a new mix design of concrete grout was developed using locally available materials and investigated under two curing conditions and workability, compressive strength, Accelerated Mortar Bar Test (AMBT), water absorption, volume of permeable voids (VPV), Sorptivity and 90-days salt ponding test were conducted. The compressive strength of concrete grout at the age 90 days was found to be 44.49 N/mm2 under water curing. It was observed that the percentage of mortar bar length change was below 1% for developed concrete grout. The water absorption of the concrete grout was in between the range of 0.88 % to 3.60 % under two different curing up to the age 90 days. It was also observed that the VPV of concrete was in the range of 0 % to 9.75 and 2.44% to 13.05% under water curing and site curing respectively. It was found that the Sorptivity of the concrete grout under water curing at the age of 28 days is 0.211mm/√min and at the age 90 day are 0.067 mm/√min. The chloride content decreased greatly, 90% after a depth of 15 mm. It was noticed that the site cured samples showed higher chloride contents near surface compared to water cured samples. This investigation suggested that the developed mix design of concrete grout using locally available construction materials can be used for crack repairing of existing RC structures in Sabah.

Keywords: Concrete grout, Salt ponding, Sorptivity, Water absorption.

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Authors: Dariush Semnani, Javad Yekrang, Hossein Ghayoor

Abstract:

Concerning the measurement of friction properties of textiles and fabrics using Kawabata Evaluation System (KES), whose output is constrained to the surface friction factor of fabric, and no other data would be generated; this research has been conducted to gain information about surface roughness regarding its surface friction factor. To assess roughness properties of light nonwovens, a 3-dimensional model of a surface has been simulated with regular sinuous waves through it as an ideal surface. A new factor was defined, namely Surface Roughness Factor, through comparing roughness properties of simulated surface and real specimens. The relation between the proposed factor and friction factor of specimens has been analyzed by regression, and results showed a meaningful correlation between them. It can be inferred that the new presented factor can be used as an acceptable criterion for evaluating the roughness properties of light nonwoven fabrics.

Keywords: Surface roughness, Nonwoven, Machine vision, Image processing.

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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

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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: Anita Khadka, Gregory Epiphaniou, Carsten Maple

Abstract:

There is a dramatic surge in the adoption of Machine Learning (ML) techniques in many areas, including the nuclear industry (such as fault diagnosis and fuel management in nuclear power plants), autonomous systems (including self-driving vehicles), space systems (space debris recovery, for example), medical surgery, network intrusion detection, malware detection, to name a few. Artificial Intelligence (AI) has become a part of everyday modern human life. To date, the predominant focus has been developing underpinning ML algorithms that can improve accuracy, while factors such as resiliency and robustness of algorithms have been largely overlooked. If an adversarial attack is able to compromise the learning method or data, the consequences can be fatal, especially but not exclusively in safety-critical applications. In this paper, we present an in-depth analysis of five adversarial attacks and two defence methods on a crack detection ML model. Our analysis shows that it can be dangerous to adopt ML techniques without rigorous testing, since they may be vulnerable to adversarial attacks, especially in security-critical areas such as the nuclear industry. We observed that while the adopted defence methods can effectively defend against different attacks, none of them could protect against all five adversarial attacks entirely.

Keywords: Resilient Machine Learning, attacks, defences, nuclear industry, crack detection.

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

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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: 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: I. Razmi, N. Choupani

Abstract:

The incidence of mechanical fracture of an automobile piston rings prompted development of fracture analysis method on this case. The three rings (two compression rings and one oil ring) were smashed into several parts during the power-test (after manufacturing the engine) causing piston and liner to be damaged. The radial and oblique cracking happened on the failed piston rings. The aim of the fracture mechanics simulations presented in this paper was the calculation of particular effective fracture mechanics parameters, such as J-integrals and stress intensity factors. Crack propagation angles were calculated as well. Two-dimensional fracture analysis of the first compression ring has been developed in this paper using ABAQUS CAE6.5-1 software. Moreover, SEM fractography was developed on fracture surfaces and is discussed in this paper. Results of numerical calculations constitute the basis for further research on real object.

Keywords: Compression piston ring, Crack, Fracture mechanics, SEM fractography.

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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: Ahmet Turer

Abstract:

Middle-gate is located in Hasankeyf, Batman dating back to 1800 BC and is one of the important historical structures in Turkey. The ancient structure has suffered major structural cracks due to aging as well as lateral pressure of a cracked rock which is predicted to be about 100 tons. The existing support system was found to be inadequate to support the load especially after a recent rock fall in the close vicinity. Concerns were increased since the existing support system that is integral with a damaged and cracked gate wall needed to be replaced by a new support system. The replacement process must be carefully monitored by crackmeters and control mechanisms should be integrated to prevent cracks to expand while the same crack width needs to be maintained after the operation. The control system and actions taken during the intervention are explained in this paper.

Keywords: structural control, crack width, replacement, support

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Authors: Parisa Hasanpour, Bahram Borooghani, Vahid Asadi

Abstract:

In the current research, a catastrophic failure of a 304 stainless steel flange at pipeline transportation of ethylene in a petrochemical refinery was studied. Cracking was found in the flange after about 78840h service. Through the chemical analysis and tensile tests, in addition to microstructural analysis such as optical microscopy and Scanning Electron Microscopy (SEM) on the failed part, it found that the fatigue was responsible for the fracture of the flange, which originated from bumps and depressions on the outer surface and propagated by vibration caused by the working condition.

Keywords: Failure analysis, 304 stainless steel, fatigue, flange, petrochemical refinery.

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Authors: Mahdi Fakoor, Seyed Mohammad Navid Ghoreishi

Abstract:

Investigation of fracture of wood components can prevent from catastrophic failures. Created fracture process zone (FPZ) in crack tip vicinity has important effect on failure of cracked composite materials. In this paper, a failure criterion for fracture investigation of cracked wood specimens under mixed mode I/II loading is presented. This criterion is based on maximum strain energy release rate and material nonlinearity in the vicinity of crack tip due to presence of microcracks. Verification of results with available experimental data proves the coincidence of the proposed criterion with the nature of fracture of wood. To simplify the estimation of nonlinear properties of FPZ, a damage factor is also introduced for engineering and application purposes.

Keywords: Fracture criterion, mixed mode loading, damage zone, microcracks.

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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: 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: S. R. Hosseini, N. Choupani, A. R. M. Gharabaghi

Abstract:

The modified Arcan fixture was used in order to investigate the mixed mode fracture properties of high strength steel butt weld through experimental and numerical analysis. The fixture consisted of a central section with "butterfly-shaped" specimen that had central crack. The specimens were under pure mode I (opening), pure mode II (shearing) and all in plane mixed mode loading angles starting from 0 to 90 degrees. The geometric calibration factors were calculated with the aid of finite element analysis for various loading mode and different crack length (0.45≤ a/w ≤0.55) and the critical fracture loads obtained experimentally. The critical fracture toughness (KIC & KIIC) estimated with experimental and numerical analysis under mixed mode loading conditions.

Keywords: Arcan specimen, fracture toughness, mixed mode, steel weld.

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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: S.C. Chin, N. Shafiq, M.F. Nuruddin

Abstract:

To date, theoretical studies concerning the Carbon Fiber Reinforced Polymer (CFRP) strengthening of RC beams with openings have been rather limited. In addition, various numerical analyses presented so far have effectively simulated the behaviour of solid beam strengthened by FRP material. In this paper, a two dimensional nonlinear finite element analysis is presented to validate against the laboratory test results of six RC beams. All beams had the same rectangular cross-section geometry and were loaded under four point bending. The crack pattern results of the finite element model show good agreement with the crack pattern of the experimental beams. The load midspan deflection curves of the finite element models exhibited a stiffer result compared to the experimental beams. The possible reason may be due to the perfect bond assumption used between the concrete and steel reinforcement.

Keywords: CFRP, large opening, RC beam, strengthening

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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: Md. Ashikur Rahman Khan, M. M. Rahman

Abstract:

Electrical discharge machining (EDM) is a relatively modern machining process having distinct advantages over other machining processes and can machine Ti-alloys effectively. The present study emphasizes the features of the development of regression equation based on response surface methodology (RSM) for correlating the interactive and higher-order influences of machining parameters on surface finish of Titanium alloy Ti-6Al-4V. The process parameters selected in this study are discharge current, pulse on time, pulse off time and servo voltage. Machining has been accomplished using negative polarity of Graphite electrode. Analysis of variance is employed to ascertain the adequacy of the developed regression model. Experiments based on central composite of response surface method are carried out. Scanning electron microscopy (SEM) analysis was performed to investigate the surface topography of the EDMed job. The results evidence that the proposed regression equation can predict the surface roughness effectively. The lower ampere and short pulse on time yield better surface finish.

Keywords: Graphite electrode, regression model, response surface methodology, surface roughness.

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