Papers by Keyword: Surface Finish

Abstract: As 3D printing technology continues to advance, it offers unprecedented opportunities to manufacture complex components such as gears. This study investigates the influence of various variables associated with 3D printing, particularly using the fused deposition modeling (FDM) method, on the surface finish of gears. Additionally, it outlines future research directions aimed at understanding how surface finish behavior correlates with wear resistance. The research begins with an in-depth analysis of the key variables involved in 3D printing gears using the FDM technique. These variables include extrusion temperature, printing speed and layer height. By systematically varying these parameters, the study aims to find their individual and collective effects on the surface finish of 3D printed gears. Experimental tests are carried out to evaluate the impact of each variable on the quality of the surface finish. Parameters such as surface roughness, uniformity of material deposition and layer adhesion are meticulously evaluated. The results demonstrate that variables such as extrusion temperature and layer height exert a significant influence on gear surface finish, while printing speed may have less pronounced effects. In summary, this study highlights the importance of understanding how various 3D printing variables affect gear surface finish and wear behavior. It identifies future areas of research that could provide a better understanding of these phenomena and lead to significant advances in the manufacturing of 3D printed gears.

Abstract: Electropolishing has been widely used for surface finishing of metallic products in the industry, owing to its excellent capability of producing metallic components with a homogeneously smooth surfaces. However, this treatment is often constrained by the long duration required for the processing. Therefore, an improvement in this process is needed. The aim of this research is to introduce the use of electropolishing with circulated electrolytes for improving the surface finish of brass. In this work, electropolishing was carried out by using circulated H₂SO₄ electrolyte for 10 to 30 min in a customized electropolishing chamber. The effect of this treatment on surface morphology, surface roughness, and thickness reduction of the brass specimen was determined. The results showed a better capability of electropolishing with circulated electrolyte in decreasing the brass roughness, i.e., by 84%, than that without electrolyte circulation which only reached 45% during 30 min of the treatment.

Abstract: The end milling process plays a crucial role in shaping the material into surface structures that meet the stringent requirements of these demanding industries. The present paper aims to optimize the end milling process of Al6061 with nano tungsten carbide reinforcement at 6% by studying metal removal rate (MRR), and surface finish based on the parameters of depth of cut, feed, and cutting speed. The aluminium metal matrix composite is prepared with 6 weight percentage of nano tungsten carbide is reinforced with Al6061 alloy is casted by using stir casting method. RSM analysis is used to find the best operating condition by using L9 orthogonal array. The ANOVA result shows that cutting speed is the most domineering factor which influences the MRR and feed rate is the most influencing factor on surface roughness.

Abstract: An overview of the additive/subtractive hybrid manufacturing (ASHM) research on three heat resisting materials – 18Ni-300 maraging steel, 316L stainless steel, and Inconel 718 (hereinafter 18Ni-300, 316L and IN718) – is provided to bridge key knowledge gaps and establish the respective process-microstructure-property relationships. The results examine validating the final surface roughness properties in the as-built and machined conditions in terms of the linear and areal parameters. Microscopic observations are also detailed to identify the influence of dry machining intermittent passes and/or laser conditions on microstructural features, as well as the bulk density. Mechanical stability assessment involved hardness measurement and tensile testing to evaluate the mechanical response of the materials built by in-envelope ASHM.

Abstract: The advantages of non-contact digitising systems over contact systems are undeniable. They allow capturing more information per unit of time with less accessibility problems and without alter the digitised surface. Although many of these systems have been developed with the aim of replacing contact systems in metrological verification tasks, generalist techniques such as photogrammetry, structured light, etc., have been developed over the years for digitising archaeological remains, works of art or living biological systems, among others. As is the case for non-contact measurement-oriented systems, for these generalist systems there are still difficulties in positioning them along a metrological traceability chain if they are required for any kind of measurement. This is due to the lack of specific standards, as well as the strong influence of the optical properties of the digitised surface on the quality of the results obtained. It is therefore necessary to develop calibration procedures and characterisation work to analyse this influence. The aim of this work is to characterise the metrological performance of one of these generalists structured light devices, Einscan-SP by Shining 3D, in the digitising of different calibration spheres made of different materials (WC, Al₂O₃, ZrO₂, etc.) with different surface finishes (shot-blasted, polished, coated). As quality indicators, the number of points captured, the quality of the point cloud as well as the dimensional and geometrical deviation from the results obtained with a high-performance contact measurement system shall be used. Apart from the raw data, the influence of applying filtering to the captured clouds is analysed. The results of this work allow recommendations to be made regarding the material and finish of the spheres to be used, as well as the filtering to be applied, if necessary, in order to assess the metrological performance of this type of equipment.

Abstract: Flat bottom drills at a point angle of 180 deg. have recently been applied to not only drilling on inclined surfaces but also flat bottom holes in terms of the dimensional accuracy and the process efficiency. Controlling the cutting force, the tool damage, and the surface finish, the corner shape is a critical parameter in the design of the flat bottom drill. The paper discusses the effect of the corner radius on the cutting forces and the surface finish in drilling with flat bottom drills. The typical differences in the cutting force are confirmed during the edge engagement. Then, the cutting force is simulated with a chip flow model, in which the chip flow angle is determined to minimize the cutting energy. The cylinder surface finishes and the burr formations are associated with the chip flow direction and the uncut chip thickness at the end of the lip.

Abstract: A study on the dimensional tolerance for CO₂ laser wood cutting is focused on the Meranti (Shorea) wood with the thickness of 19 mm. The results on kerf width for two surfaces which are top surface (K_t) and bottom surface (K_b) are investigated. It is interested to find out the optimum cutting parameters to achieve the smallest variance on top and bottom kerf to improve dimensional quality. Laser power, cutting speed, and gas pressure had been selected as investigate parameters and the cut kerf had been analysed. The investigations revealed that laser power and cutting speed are the significant parameters not only in producing a good surface finish, but also in yielding much narrower kerf with to ensure there will be no dimensional errors of the shore wood products. Besides quality, the laser processing approach has overcome most of the challenges faced by conventional production method.

Abstract: Additive Manufacturing (AM) has shown great potential for efficient realization of complicated microdevices fabricated with higher freedom of design and made from a wide variety of materials suiting to their specific target functionalities. Capability of generation of components with reduced weights, higher part consolidation, greater customization offered along with minimal waste generation are its advantages over conventional manufacturing processes. The AM built parts, however, need to undergo relevant post processing techniques to render them fit for their end product application. The paper attempts to classify the post processing techniques and emphasize their applicability to specific AM methods, generalized procedure as well as the recent improvements undergone. The post processing techniques have been categorised as methods for support material removal, surface texture improvements, thermal and non-thermal post processing and aesthetic improvements. The main challenges to the expansion of additive manufacturing have been discussed which highlight the future, scope of improvement and research required in the area of appropriate tool path development and product quality with regards to surface roughness, resolution and porosity levels in the built part.

Abstract: Tin-Silver-Copper (SnAgCu) lead-free solder on Electroless Nickel Immersion Gold (ENiG) and Immersion Tin (ImSn) surface finish printed circuit board was subjected to blast test. A variation of intermetallic compounds (IMC) layer, hardness and reduced modulus of soldered sample exposed to blast test were intensively investigated using optical microscope and nanoindentation machine. Formation of IMCs due to reaction between solder and substrate during blast test provided deleterious effect of metallurgical bond strength and reliability on the solder joint. Microstructural analysis was evaluated via Infinite Focused Microscope (IFM). The findings of these studies indicate that best surface finished for blast test performance was not necessarily the best surface finish for optimum reliability. ENiG and ImSn surface finish can be advantage or a disadvantage depending on the application, package and reliability requirements. As a result, most component assemblers are using ENiG and ImSn in order to improve solderability as well as the wettability between solder and the substrate and to meet various package requirements.

Abstract: Glass, being considered as hard and brittle material is very difficult to machine into desired shapes. The readily available conventional machining process does not provide good surface finish thus requires additional machining process. This paper reviews the different existing non conventional machining process accessible till today for the machining of glass materials. This paper also discusses the advantages and disadvantages of the existing non conventional machining processes. The various hybrid non conventional machining processes are also studied with focus on machining output characteristics like MRR, surface finish, tool wear rate. This paper summarizes the selection of hybrid non conventional machining processes for the various type of glass.