Papers by Keyword: Surface Roughness

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Authors: Mohannad Naeem Houshi
Abstract: In the nanotechnology era, the need for products with high quality and surfaces with free-from damage has become an urgent necessity. Many components in the precision industries such as electronics, automobile, medical, and aviation require high surface finish to meet their functional requirements, such as, reducing fluid flow resistance, friction, optical losses and increase fatigue strength. However, the scale of such surface quality cannot be achieved by traditional finishing methods. To overcome these limitations, many advanced finishing processes have been developed such as abrasive flow finishing, magnetorheological fluid finishing, magnetic float polishing, and chemical mechanical polishing and magnetic abrasive finishing. Magnetic abrasive finishing (MAF) is one of advanced finishing processes which offers superior surface finish over conventional finishing processes, because of its self-adaptability to finish of different geometric shapes, its a gentle tool which does not impact workpiece surface, its capability to polish advanced engineering materials and its low cost. This article has been focused on MAF, as well as reviewing of advanced finishing processes. The recent researches and challenges of MAF have been discussed as well.
Authors: Csaba Felho, János Kundrák
Abstract: A method is introduced for determining theoretical values of roughness characteristics of surfaces generated by tools having a defined edge geometry. The method is based on the CAD modelling of the theoretical cut surface, and can be used to model practically any complex tool geometry. In application to rotating tools (e.g. face milling), besides the variety of tool designs, the setting accuracy was also taken into consideration during the determination of theoretical values due to the simultaneous cutting of more than one edge. It will be demonstrated that in addition to the determination of 2D roughness parameters, the method is suitable to determine the 3D roughness parameters as the surface topography can be more accurately described with these characteristics. Experimental data is shown to validate of the extended modelling and calculation method.
Authors: Ze Fei Chen, Lang Zhang
Abstract: On the basis of uneven copper surface roughness during lathering in common CNC lather, analyze the cutting ways of copper spherical surface and the cutting layer different from cylindrical surface lathing. The cutting direction of cylindrical surface lathing is constant, and its cutting layer is too. However, the direction of spherical surface lathing varies along the tangent of its cutting point continually, and the working cutting edge angle and the working minor cutting edge angle of the cutting tool vary too, so the theoretical surface roughness is affected. The cutting layer of spherical surface lathing varies continually, so does the cutting depth of its every cutting point. Through analysis and experiments, prove that cutting force variety is caused by the gradient variety of cutting depth, which leads to increase of the surface rough and its unevenness. Based on the research result, design some new cutting path to improve the surface roughness of copper spherical surface lathing, and obtain good effect.
Authors: Mei Xia Yuan, Xi Bin Wang, Li Jiao, Yan Li
Abstract: Micro-milling orthogonal experiment of micro plane was done in mesoscale. Probability statistics and multiple regression principle were used to establish the surface roughness prediction model about cutting speed, feed rate and cutting depth, and the significant test of regression equation was done. On the basis of successfully building the prediction model of surface roughness, the diagram of surface roughness and cutting parameters was intuitively built, and then the effect of the cutting speed, feed rate and cutting depth on the small structure surface roughness was obtained.
Authors: Leonardo De Chiffre, Ö.C. Kücükyildiz, Niels Bay
Abstract: A simple theoretical model linking surface micro geometry, friction and manufacturing cost is presented. Combining a basic geometrical relationship of plastic deformation of workpiece surface asperities by a hard tool with an assumption of adhesive friction, the friction coefficient of a soft, rough surface sliding against a hard, smooth tool surface can be calculated, linking surface roughness with friction coefficient. The simple model can also link the cost related to manufacturing with a surface characterized by a given friction coefficient value. Results are presented from tests carried out to verify the simple model. Several test pieces were manufactured by turning, or grooving, an aluminum alloy and brass using different feeds, tool nose radii, and tool nose angles, achieving different surface profiles. The surfaces were characterized using a stylus profilometer and a digital microscope. The static friction coefficient was determined in terms of angle of repose using a rotary table. The experimentally determined values of the friction coefficient were compared with those predicted from feed, tool radius, and asperity angle. The tests have shown a good reproducibility, and a clear determination of the friction coefficient was possible. However, due to the low normal loads involved in this set up, the influence from the surface roughness was not clear. Further investigations are therefore proposed.
Authors: R. Ganesh, R. Satyaprakash, M. Prakash, Chandrasekaran Kesavan
Abstract: This paper aims to understand the influence of sintering temperature on the drilling performance of Al 2219 – SiCp composite. This type of composite is currently used in aerospace and transportation industries. Drilling is the most frequently employed operation of secondary machining owing to the need for fabrication. This composite is usually subjected to precipitation heat treatment and needs the study of influence of sintering temperature on machining performance. The composite is fabricated through powder metallurgy route. The drilling tests are conducted with PCD drill of 5 mm diameter and 118° point angle. The experiments are conducted under conditions of different spindle speeds of 500, 1000 and 1500 rpm and feed rates of 10, 15 and 20 mm/min. Specific cutting pressure and surface roughness of the hole are considered as performance indicators during the study. Weight fraction of the reinforcement and sintering temperature are found to have significant influence on the drilling performance of the composites.
Authors: Ondřej Bílek, Jitka Baďurová, Jiří Čop
Abstract: In this study, the surface grinding was performed at different feed rates and depth of cuts. Grindability of engineering thermoplastics and metals was evaluated. Further, important process parameters influencing surface quality were determined using analysis of variance (ANOVA). Experimental results compared two significantly different groups of materials in order to emphasize common variables. Finally, further research directions were presented to seek for functional relation between process parameters and grindability.
Authors: Yong Wang, Hong Tao Zhu, Chuan Zhen Huang, Jun Wang, Peng Yao
Abstract: Abrasive waterjet machining is considered as a promising technique in hard-brittle material polishing. In this paper, The ultrasonic torsional vibration is considered to apply on the workpiece to improve the abrasive waterjet polishing quality and efficiency. The process parameters in the ultrasonic torsional vibration-assisted abrasive waterjet polishing are optimized. The ultrasonic torsional vibration in the role of the abrasive waterjet polishing is investigated. The results show that the application of ultrasonic torsional vibration can effect of abrasive particle movement and increase the critical depth of the ceramic materials.
Authors: A.M.M. Sharif Ullah, M.A.K. Chowdhury, Akihiko Kubo
Abstract: This paper presents a surface generation mechanism of grinding that captures the microscopic interaction between the abrasive grains and work-surface. The mechanism utilizes both deterministic and stochastic formulations and deals with such realistic constraints as loss/wear and uneven distribution of abrasive grains, roughness of already-ground work-surface, and machine stiffness. Apart from the theoretical treatments, numerical examples are cited showing how the topography of the work-surface evolves because of the proposed mechanism. The work will help build computerized systems ensuring a reliable prediction of the surface roughness due to grinding under the realistic constraints.
Authors: István Szalóki, Sándor Sipos, Zsolt János Viharos
Abstract: Cutting of metal matrix composites (MMCs) has been considerably difficult due to the extremely abrasive nature of the reinforcements causing rapid tool wear and high machining cost. In this experimental study, three aluminium-based metal matrix composites (MMCs) were produced using a high pressure infiltration. Machining tests were carried out by face milling on the MMCs using coated carbide (HM) cutting tool at various values of feed rate, width of cut and depth of cut, under a constant cutting speed. The effect of the varied parameters on the surface roughness was investigated. The obtained results indicate that the Rz and Rp parameters are more capable to describe the influence of the milling parameters on the surface quality.
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