Effect of micro-scale Young’s modulus and surface roughness on adhesion property to plasma-treated rubber surface

Adhesion between rubbers and metals is often the main cause of machine trouble. Therefore, efficient utilization of rubber in dynamic and static applications requires the modification of the adhesion property of the rubber surface without affecting the bulk characteristics. In this work, we have studied the mechanism of the reduction in adhesion force between medical rubber, chloride-isobutene-isoprene rubber (CIIR), and stainless steel by using surface wave-excited plasma treatment of the rubber surface with oxygen and argon gases. Experimental results showed that surface roughness derivations increased by about 10 times across the treatment, at maximum, corresponding to the increase in time. In addition, the micro-scale Young’s modulus of treated CIIR sheet increased by about 6.3 times at maximum from that of the untreated CIIR sheet. These changes in Young’s modulus and roughness at the surface of CIIR sheet are considered to be the main reasons for the plasma-assisted reduction of adhesion force between stainless steel ball (SUS 440C, JIS) and CIIR sheet.     

Selective metallization of polymers using laser induced surface activation (LISA)��characterization and optimization of porous surface topography

Laser induced selective activation (LISA) is a molded interconnected devices technique for selective metallization of polymers. On the working piece, only the laser-machined area can be metalized in the subsequent plating. The principle of the technology is introduced. Surface analysis was performed on the laser-machined polymer using an Alicona InfiniteFocus? microscope. Based on previous experiments, bearing area curve and its parameters are chosen to characterize the surface. In this paper, by comparison of plateable and non-plateable surfaces, and two types of plateable surface made by different lasers, it is found that the normalized bearing area curve is an effective method to characterize porous surface for the subsequent plating. The normalized parameters are available to make a quantitative analysis.     

Design and application of a borehole–surface microseismic monitoring system

Borehole–surface microseismic monitoring is a new approach for monitoring artificially induced hydraulic fracturing in an oil or gas field. However, ineffective communication links and incompatible data formats between current borehole- and surface-based monitoring systems mean that borehole–surface monitoring cannot be reported in real time. To solve this problem, the borehole–surface microseismic monitoring system reported here allows fracturing points through inversion and the development of fractures to be viewed in real time. Private cloud technology is used to control the instruments, manage the borehole and the surface database, and process the data. This system ensures high performance and availability of the system. The data acquisition modules and the geophones used in the borehole and surface instruments were calibrated in the laboratory to ensure the consistency of the acquired microseismic signals. The monitoring system located 82 microseismic events with a fracture azimuth of N84°E during fracture production in the Daqing Oilfield. Subsequent analysis showed that the locations of the fractures and their strike directions were consistent with the theory of hydraulic fracture propagation and the local crustal stress field. The results demonstrate that the monitoring system effectively and promptly processed data, thus enabling real-time borehole–surface microseismic monitoring.     

Effect of strain amplitude and temperature on creep-fatigue behaviors of 9–12 % Cr steel

The creep-fatigue behaviors of P92 steel under strain range of 0.3 %–0.5 % and test temperature of 600–650 °C was studied carefully in this paper. With the increase of temperature, the creep-fatigue life is significantly reduced, and more vulnerable to temperature than strain amplitude. In addition, the dislocation density decreases with increasing creep fatigue, and the martensite laths become coarser. Furthermore, the increase of strain amplitude leads to more significant secondary cracks and fatigue striation. The higher temperature causes much deeper and larger dimples. During the test, the growth and accumulation of precipitates inevitably lead to stress concentration, resulting in material fracture and destruction. Finally, the linear cumulative damage (LCD), the modified ductility exhaustion (MDE) and the frequency separation life (FSL) model are used to predict the creep-fatigue life of P92 steel, and it is found that the frequency separation life model had the highest prediction accuracy among the threes.

     

Variable amplitude fatigue crack growth behavior — a short overview

A short overview concerning variable amplitude (VA) fatigue crack growth behavior is presented in this paper. The topics covered in this review encompass important issues pertaining to both single and repeated overload transients. Reviews on transient post overload effects such as plasticity induced crack closure, crack tip blunting, residual stresses, crack deflection and branching, activation of near threshold mechanisms, strain hardening are highlighted. A brief summary on experimental trends and finite element modelling of overload induced crack closure is also presented.     

Surface separation and contact resistance considering sinusoidal elastic–plastic multi-scale rough surface contact

The current work considers the multi-scale nature of surface roughness in a new model that predicts the real area of contact and surface separation as functions of load. This work is based upon a previous rough surface multi-scale contact model which used stacked elastic–plastic spheres to model the multiple scales of roughness. Instead, this work uses stacked 3D sinusoids to represent the asperities in contact at each scale of the surface. By summing the distance between the two surfaces at all scales, a model of surface separation as a function of dimensionless load is obtained. Since the model makes predictions for the real area of contact, it is also able to make predictions for thermal and electrical contact resistance. In accordance with concerns in previous works that the iterative calculation of the real contact area in multi-scale methods does not converge, this work not only tests but also gives conditions required for convergence in these techniques. The results are also compared to other existing rough surface contact models.     

Optimization of surface treatment to enhance fiber–matrix interface and performance of composites

Oxidation treatment with concentrated HNO₃ was employed to the carbon fabric (CF) for various time intervals (30–180 min) to observe the effect of treatment on two simultaneous processes involved viz. improvement in its adhesion with the matrix and reduction of fiber strength which in turn is responsible for change in the performance properties of composites. Seven composites with untreated and acid treated CF were developed based on the polyetherimide (PEI) matrix and evaluated for adhesive wear properties under various loads (200–600 N) against mild steel disc. 90 min treated CF composite indicated the best tribological properties and showed 30% reduction in specific wear rate (K₀) and 23% in coefficient of friction (μ) respectively at 600 N load. Treatment beyond this time proved detrimental for improvement in properties. Field emission scanning electron microscopy (FE-SEM) showed increase in roughness with treatment time, while atomic force microscopy (AFM) studies indicated substantial increase in roughness value. Scanning electron microscopy (SEM) of worn surfaces supported the wear mechanisms and improvement in adhesion between fiber and matrix.     

Friction‐generated surface deposits

Recent publications are reviewed that illustrate friction and wear reductions by friction‐generated surface coatings in a number of applications. The emphasis is on surface chemistry. Topics included are the friction of polymers with and without fillers, the friction of metals and ceramics, friction and wear related to computer disk and tape drives, friction and wear reduction in atmospheres of carbonaceous gases, and chemical reactions between tribological surfaces with and without lubricants. This revised version was published online in September 2006 with corrections to the Cover Date.     

Performance and surface alloying characteristics of Cu–Cr and Cu–Mo powder metal tool electrodes in electrical discharge machining

The main objective of this study is to investigate the effect of Cu–Cr and Cu–Mo powder metal (PM) tool electrodes on electrical discharge machining (EDM) performance outputs. The EDM performance measures used in the study are material removal rate (MRR), tool electrode wear rate (EWR), average workpiece surface roughness (R_a), machined workpiece surface hardness, abrasive wear resistance, corrosion resistance, and workpiece alloyed layer depth and composition. The EDM performance of Cu–Cr and Cu–Mo PM electrodes produced at three different mixing ratios (15, 25, and 35 wt% Cr or Mo), compacting pressures (P_c = 600, 700, and 800 MPa), and sintering temperatures (T_s = 800, 850, and 900 °C) are compared with those machined with electrolytic Cu and Cu PM electrodes when machining SAE 1040 steel workpiece. Analyses revealed that tool materials were deposited as a layer over the work surface yielding high surface hardness, strong abrasion, and corrosion resistance. Moreover, the mixing ratio, P_c, and T_s affect the MRR, EWR, and R_a values.     

“Multimode vibration cutting” – A new vibration cutting for highly-efficient and highly-flexible surface texturing

This paper proposes a new vibration cutting method named “multimode vibration cutting” for precision surface texturing. The proposed cutting method utilizes multiple unidirectional vibration modes mainly in the depth-of-cut direction. The vibrations at multiple frequencies induced to the tool tip can generate not only sinusoidal but also highly-flexible trajectories such as trapezoidal, triangular, and distorted triangular waves. Notably, only a sinusoidal vibration can be induced when a single resonant vibration is applied to the tool tip. Compared to conventional highly-flexible cutting methods for surface texturing, such as the utilization of fast tool servo and amplitude control of ultrasonic elliptical vibration cutting, the proposed method is highly-efficient because of its direct usage of high resonant frequencies. Compared to conventional highly-efficient cutting methods for surface texturing, such as linear and elliptical vibration cutting which mainly utilizes the vibration component in the depth-of-cut direction, the proposed method can generate highly-flexible trajectories for various micro texture profiles. In this study, an ultrasonic multimode vibration device is developed, and the mechanics of generating multimode vibrations are demonstrated. Turning experiments with several texture profiles are performed to confirm the validity of the proposed method for highly-efficient and highly-flexible micro/nano surface texturing.     

表面织构(surface texture)

surface texture,在产品几何量技术规范（GPS）表面结构系列标准中有这词.ISO 4287：1997《产品几何量技术规范（GPS）表面结构：轮廓法 表面结构的术语、定义及参数》中没有给出surface texture的定义.     

Enhancement and verification of a machined surface quality for glass milling operation using CBN grinding tool—Taguchi approach

Nowadays, the demand for high product quality focuses extensive attention to the quality of machined surface. The (CNC) milling machine facilities provides a wide variety of parameters set-up, making the machining process on the glass excellent in manufacturing complicated special products compared with other machining processes. However, the application of grinding process on the CNC milling machine could be an ideal solution to improve the product quality, but adopting the right machining parameters is required. Taguchi optimization method was used to estimate optimum machining parameters with standard orthogonal array L₁₆ (4⁴) to replace the conventional trial and error method as it is time-consuming. Moreover, analyses on surface roughness and cutting force are applied which are partial determinant of the quality of surface and cutting process. These analyses are conducted using signal to noise (S/N) response analysis and the analysis of variance (Pareto ANOVA) to determine which process parameters are statistically significant. In glass milling operation, several machining parameters are considered to be significant in affecting surface roughness and cutting forces. These parameters include the lubrication pressure, spindle speed, feed rate, and depth of cut as control factors. While, the lubrication direction is considered as a noise factor in the experiments. Finally, verification tests are carried out to investigate the improvement of the optimization. The results showed an improvement of 49.02% and 26.28% in the surface roughness and cutting force performance, respectively.     

Precision nanometrology of a large areamicrostructured metrology surface

1 Introduction The authors have been working on a newsurface encoder for detecting multi-degree-of-freedom(MDOF) translational and tilt motionsof precision stages[1]. The surface encoder con-sists of two fundamental elements: a sinusoidalmicrostructured metrology surface, which is re-ferred to as the angle grid, and a two-dimension-al (2D) slope sensor[2-3].     

Analysis of surface roughness and cutting force when turning AISI 1045 steel with grooved tools through Scott–Knott method

The chip breaker presents an important role in chip control on turning operation, as well as a significant influence on cutting force, surface integrity, wear, and tool life. In this experimental study, the grooved chip breaker, feed rate, and cutting velocity influence on cutting force and surface roughness of turning process of AISI 1045 steel were investigated through a complete factorial design and the Scott–Knott method. The multiple comparison method of Scott–Knott was used to identify which combination of the factor levels was specifically different when a source of variation was statistically significant in ANOVA. This multiple comparison method was essential to choose an optimal combination between cutting conditions and chip breaker type assuring the lowest cutting force and surface roughness levels without ambiguity. The methodology proposed was effective at achieving process improvement.     

A РИТМ-СП facility for the surface alloying

A combined РИТМ-СП facility intended for forming thin alloy layers on the sample surface during the single vacuum cycle (in situ) is described. The facility consists of a low-energy (10–30 keV) high-current (up to 25 kA) pulsed (2–4 μs) electron beam source and a magnetron sputtering device mounted together with the electron gun of the source on the common vacuum working chamber. The chamber is equipped with the manipulator intended to move the working table with samples without vacuum failures. The facility contains a computer-aided system for controlling the pumping, filling of the chamber with the working gas, power supply units, synchronization of pulse processes during the generation of the electron beam, deposition of films, displacements of the sample, etc. To illustrate the operation of the facility, results of experiments on surface alloying for the Ni-Cu system are given.     

Precision nanometrology of a large area microstructured metrology surface

1　Introduction　　Theauthorshavebeenworkingonanewsur faceencoderfordetectingmulti degree of freedom(MDOF)translationalandtiltmotionsofprecisionstages[1] .Thesurfaceencoderconsistsoftwofun damentalelements :asinusoidalmicrostructuredmetrologysurface ,whichisreferredtoastheanglegrid ,andatwo dimensional( 2D)slopesensor[2 3 ] .Theanglegridhasa 3Dmicrostructuredsur face ,whichisasuperpositionofsinusoidalwavesintheX andY directions.Sincetheanglegridsur faceisusedasthereferenceofpositionmeasur…     

Effect on crystalline structure of AISI M2 steel using tungsten–thorium electrode through MRR,EWR, and surface finish

To investigate on the crystalline structure of AISI M2 steel by using tungsten–thorium electrode in electrical discharge machining (EDM) process was studied. Furthermore, the investigation were carried out for finding the value of material removal rate (MRR), electrode wear rate (EWR) and surface roughness (SR) of tool steel material depending upon three variable input process parameters. On the basis of weight loss, the value of MRR and EWR were calculated at optimized process parameter. Subsequently, surface topography of the processed material were examined through different characterization techniques like scanning electron microscopy (SEM), Optical surface profiler (OSP) and Atomic force microscopy (AFM), respectively. In XRD study, broadening of the peak was observed which confirmed the change in material properties due to the homogeneous dispersion of the particles inside the matrix. Lowest surface roughness and MRR of 0.001208 mg/min was obtained. Minimum surface roughness was obtained 1.12 μm and 2.18427 nm by OSP and AFM study, respectively. Also, minimum EWR was found as 0.013986 mg/min.     

Influence of milling on surface integrity of Ti6Al4V—study of the metallurgical characteristics: microstructure and microhardness

The quality of titanium alloy parts in the aeronautical field demands high reliability, which is largely related to surface integrity. Surface integrity is generally defined by three parameters: a geometric parameter, a mechanical parameter and a metallurgical parameter. The present article addresses the influence of milling on the metallurgical parameter for a surface milled in Ti6Al4V material, focusing in particular on the microstructure and microhardness. Observation of the machined surface from a macroscopic perspective highlight an orange peel phenomenon. This effect is the combined result of redeposition and crushing of the milled material. No plastically deformed layer or lengthening of the grains was observed under the milled surface. As far as microhardness is concerned, a slightly softened region was observed under the milled surface. A diffusion of vanadium from the β phase to the α phase was also noted, but with no change in microstructure.     

In-process prediction of surface roughness in turning of Ti–6Al–4V alloy using cutting parameters and vibration signals

In this work, an attempt has been made to use vibration signals for in-process prediction of surface roughness during turning of Ti–6Al–4V alloy. The investigation was carried out in two stages. In the first stage, only acceleration amplitude of tool vibrations in axial, radial and tangential directions were used to develop multiple regression models for prediction of surface roughness. The first and second order regression models thus developed were not found accurate enough (maximum percentage error close to 24%). In the second stage, initially a correlation analysis was performed to determine the degree of association of cutting speed, feed rate, and depth of cut and the acceleration amplitude of vibrations in axial, radial, and tangential directions with surface roughness. Subsequently, based on this analysis, feed rate and depth of cut were included as input parameters aside from the acceleration amplitude of vibrations in radial and tangential directions to develop a refined first order multiple regression model for surface roughness prediction. This model provided good prediction accuracy (maximum percentage error 7.45%) of surface roughness. Finally, an artificial neural network model was developed as it can be readily integrated into a computer integrated manufacturing environment.