Surface Roughness after Milling of the Al/CFRP Stacks with a Diamond Tool

This study presents the results of research on the surface quality of hybrid sandwich structures after milling with a diamond blade tool. It identifies the effects of feed and machining strategy on the roughness and topography of the surface. It provides an analysis of Ra and Rz surface roughness parameters as well as Sp, Sz, and Sv surface topography parameters. The processed object was a two-layer sandwich structure consisting of aluminium alloy 2024 and CFRP (carbon fibre-reinforced polymer) composite. The minimum values of the Ra and Rz surface roughness parameters were obtained on the aluminium alloy surface, whereas the maximum values were obtained on the CFRP surface. The same was true for the 3D surface roughness parameters—the lowest values of Sp, Sz, and Sv parameters were obtained on the surface of the metal layer, while the highest values were obtained on the surface of the composite layer (the maximum value of the Sp parameter was an exception). A surface topography analysis has revealed a targeted and periodic pattern of micro-irregularities for the vast majority of the samples considered. The statistical analysis shows that the surface roughness of the aluminium alloy was only affected by the feed rate. For the CFRP, the feed rate and the interaction of milling strategy and feed rate (Sfz) had a statistically significant effect. The obtained results provide a basis for designing such sandwich element processing technology, for which differences in roughness and topography parameters for the component materials are lowest.

Download Full-text

Modeling of Surface Topography for Reduced Friction

Volume 3: Design; Tribology; Education ◽

10.1115/esda2008-59369 ◽

2008 ◽

Cited By ~ 2

Author(s):

Marko Sedlacˇek ◽

Bojan Podgornik ◽

Jozˇe Vizˇintin

Keyword(s):

Surface Roughness ◽

Surface Topography ◽

Surface Texturing ◽

Test Results ◽

Textured Surfaces ◽

Roughness Parameters ◽

Contact Conditions ◽

Surface Roughness Parameters ◽

Pin On Disc ◽

Texture Size

The aim of the present research was to investigate surface topography in terms of different surface roughness parameters and to correlate surface topography change to friction of contact surfaces. For this purpose, different 100Cr6 plate samples with different surface topography were prepared. Using different grades and combinations of grinding and polishing samples with similar Ra values, but different Rku and Rsk values were obtained. To evaluate influence of roughness parameters on friction and wear, dry and lubricated pin-on-disc tests were carried out under different contact conditions. Test results indicate that high Rku and negative Rsk values lead to decrease in friction. To investigate the effect of surface texturing on surface roughness parameters, real roughness profiles were virtually altered to achieve virtually textured surfaces. Using NIST SMATS softgauge for calculation of surface roughness parameters, virtually altered roughness profiles were investigated in terms of texture size, shape and spacing, and their influence on surface roughness parameters, especially on skewness and kurtosis. Lower diameter, higher spacing and wedge-shaped dimples reflect in higher Rku and more negative Rsk parameters.

Download Full-text

Research on the Surface Roughness Parameters of Micro-EDM

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.572.281 ◽

2013 ◽

Vol 572 ◽

pp. 281-286 ◽

Cited By ~ 1

Author(s):

Zhi Jie Chen ◽

Ji Hong Shen ◽

Yun Tao Dai

Keyword(s):

Surface Roughness ◽

Surface Morphology ◽

Surface Topography ◽

Evaluation Method ◽

Micro Edm ◽

Roughness Parameters ◽

Surface Roughness Parameters ◽

Evaluation Problem ◽

Lubrication Characteristics ◽

Morphology Characteristics

The surface topography errors of micro-EDM are mainly composed of surface roughness, surface waveness and so on. Research shows that the surface morphology provides a lot of useful information, which has serious influence on the friction and lubrication characteristics of the surface. However, for the micro-EDM surface topography evaluation problem, researchers have been using surface roughness parameters and evaluation method of mechanical process, which restrict the micro-EDM technology further development. On this account, the surface roughness parameters of micro-EDM have been deeply studied in this paper according to its technology characteristics and the surface morphology characteristics, therefore, the main researches and creative points are obtained, which the influence that the surface roughness of micro-EDM parts impact on their using performance is analyzed, and based on the surface morphology characteristics, some roughness evaluation parameters are given respectively according to peaks and valley, moreover, their numerical calculation are also gained.

Download Full-text

The Effect of Abrasive Waterjet Machining Parameters on the Condition of Al-Si Alloy

Materials ◽

10.3390/ma13143122 ◽

2020 ◽

Vol 13 (14) ◽

pp. 3122 ◽

Cited By ~ 1

Author(s):

Monika Kulisz ◽

Ireneusz Zagórski ◽

Jarosław Korpysa

Keyword(s):

Surface Roughness ◽

Flow Rate ◽

Surface Finish ◽

Feed Rate ◽

Abrasive Waterjet ◽

Strengthening Effect ◽

Machining Parameters ◽

Roughness Parameters ◽

Surface Roughness Parameters ◽

Sample Height

This paper analyses the effect of the abrasive waterjet cutting parameters’ modification on the condition of the workpiece surface layer. The post-machined surface of casting aluminium alloys, AlSi10Mg and AlSi21CuNi, was characterised in terms of surface roughness and irregularities, chamfering, and microhardness in order to reveal the effect that variable jet feed rate, abrasive flow rate, and sample height (thickness of the cut material) have on the quality of surface finish. From the analysis of the results, it emerges that the surface roughness remains largely unaffected by changes in the sample height h or the abrasive flow rate ma, whereas it is highly susceptible to the increase in the jet feed rate vf. It has been shown that, in principle, the machining does not produce the strengthening effect, that is, an increase in microhardness. Owing to the irregularities that are typically found on the workpieces cut with higher jet feed rates vf, additional surface finish operations may prove necessary. In addition, chamfering was found to occur throughout the entire range of speeds vf. The statistical significance of individual variables on the 2D surface roughness parameters, Ra/Rz/RSm, was determined using factorial analysis of variance (ANOVA). The results were verified by means of artificial neural network (ANN) modelling (radial basis function and multi-layered perceptron), which was employed to predict the surface roughness parameters under consideration. The obtained correlation coefficients show that ANNs exhibit satisfying predictive capacity, and are thus a suitable tool for the prediction of surface roughness parameters in abrasive waterjet (AWJ) technology.

Download Full-text

Modeling and Parameter Optimization for Surface Roughness and Residual Stress in Dry Turning Process

Engineering, Technology & Applied Science Research ◽

10.48084/etasr.1560 ◽

2017 ◽

Vol 7 (5) ◽

pp. 2047-2055

Author(s):

M. H. El-Axir ◽

M. M. Elkhabeery ◽

M. M. Okasha

Keyword(s):

Residual Stress ◽

Surface Roughness ◽

Feed Rate ◽

Rotational Speed ◽

Cutting Speed ◽

Electrochemical Analysis ◽

Depth Of Cut ◽

Roughness Parameters ◽

Etching Technique ◽

Surface Roughness Parameters

The influence of some turning variables and tool overhang on surface roughness parameters and residual stress induced due to machining 6061-T6 aluminum alloy is investigated in this paper. Four input parameters (cutting speed, feed rate, depth of cut and tool overhang) are considered. Tests are carried out by precision turning operation on a lathe. Design of experiment techniques, i.e. response surface methodology (RSM) and Taguchi's technique have been used to accomplish the objective of the experimental study. Surface roughness parameters are measured using a portable surface roughness device while residual stresses are measured employing deflection-etching technique using electrochemical analysis. The results obtained reveal that feed and rotational speed play significant role in determining the average surface roughness. Furthermore, the depth of cut and tool overhang are less significant parameters, whereas tool overhang interacts with feed rate. The best result of surface roughness was obtained using low or medium values of overhang with low speed and /or feed rate. Minimum maximum tensile residual stress can be obtained with a combination of tool overhang of 37 mm with very low depth of cut, low rotational speed and feed rate of 0.188 mm/rev.

Download Full-text

Effect of Heat Treatment on the Surfaces Topography Tested at the Cavitation Erosion from Steel 16MnCr5

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.1111.85 ◽

2015 ◽

Vol 1111 ◽

pp. 85-90 ◽

Cited By ~ 1

Author(s):

Cristian Ghera ◽

Ion Mitelea ◽

Ilare Bordeaşu ◽

Corneliu Marius Crăciunescu

Keyword(s):

Heat Treatment ◽

Surface Roughness ◽

Surface Topography ◽

Surface Hardening ◽

Cavitation Erosion ◽

Heat Treatments ◽

Roughness Parameters ◽

Surface Roughness Parameters ◽

Duplex Treatment

This paper analyzes, by comparison, the changes appeared in surface topography, for 16MnCr5 steel tested at cavitation erosion, subjected to different type of the heat treatments. The purpose of research, aimed at establishing a correlation between resistance to cavitation erosions and the surface roughness parameters, for various types of heat treatment (annealing, carburizing, Duplex treatment of carburizing, followed by the surface hardening by induction). Cavitation tests were conducted on a vibrator device with piezoceramic crystals, which fully complies with the requirements imposed by the ASTM G32 - 2010. Roughness parameters were measured using a Mitutoyo apparatus.

Download Full-text

Influence of surface functional parameters on friction behavior and elastic–plastic deformation of grinding surface in mixed lubrication state

Proceedings of the Institution of Mechanical Engineers Part J Journal of Engineering Tribology ◽

10.1177/1350650118806375 ◽

2018 ◽

Vol 233 (6) ◽

pp. 870-883 ◽

Cited By ~ 1

Author(s):

Bin Zhao ◽

Song Zhang ◽

Jianfeng Li

Keyword(s):

Surface Roughness ◽

Surface Topography ◽

Mixed Lubrication ◽

Surface Model ◽

Roughness Parameters ◽

Solid Contact ◽

Friction Behavior ◽

Surface Roughness Parameters ◽

Simulation And Experiment ◽

Friction Performance

Mixed lubrication is a common lubrication regime in sliding contact and has received much attention in recent research. The influences of surface topography on friction performance in this lubrication state are significant owing to the coexistence of fluid–solid contact and solid–solid contact conditions. First, an accuracy surface model is built based on wavelet transform results. Then, the average Reynolds equation is revised for a grinding surface to be used in simulation. Third, four surface roughness parameters ( Sa, Sbi, S ci, and Svi) are selected to characterize surface topography. Additionally, the impacts on the solid–solid contact area, friction coefficient, and surface flattening are investigated. Finally, optimizations of surface roughness parameters directed toward energy saving and sliding stability are conducted and verified. Simulation and experiment methods are jointly applied to guarantee the accuracy of this research. The result of this study can provide theoretical support for machining contact surfaces.

Download Full-text