Model-based tool condition prognosis using power consumption and scarce surface roughness measurements

In machining processes, underusing and overusing cutting tools directly affect part quality, entailing economic and environmental impacts. In this paper, we propose and compare different strategies for tool replacement before processed parts exceed surface roughness specifications without underusing the tool. The proposed strategies are based on an online part quality monitoring system and apply a model-based algorithm that updates their parameters using adaptive recursive least squares (ARLS) over polynomial models whose generalization capabilities have been validated after generating a dataset using theoretical models from the bibliography. These strategies assume that there is a continuous measurement of power consumption and a periodic measurement of surface roughness from the quality department (scarce measurements). The proposed strategies are compared with other straightforward tool replacement strategies in terms of required previous experimentation, algorithm simplicity and self-adaptability to disturbances (such as changes in machining conditions). Furthermore, the cost of each strategy is analyzed for a given benchmark and with a given batch size in terms of needed tools, consumed energy and parts out of specifications (i.e., rejected). Among the analyzed strategies, the proposed model-based algorithm that detects in real-time the optimal instant for tool change presents the best results.     

Monitoring the tool wear,surface roughness and chip formation occurrences using multiple sensors in turning

Tool wear, chip formation and surface roughness of workpiece under different cutting conditions have been investigated in machining using acoustic emission (AE) and vibration signature in turning. The investigation has shown that the AE and vibration components can effectively respond to the different occurrences in turning including tool wear and surface roughness. The AE has shown a very significant response to the tool wear progression whereas the resultant vibration (V) represented the surface roughness in turning. The vibration components V_x, V_y and V_z described the chip formation type and are found to have the most significant response to the change of feed, depth of cut and cutting speed respectively. The amplitude of vibration components, V_x, V_y and V_z increased with the increase of feed rate, depth of cut and cutting speed respectively. Even though the frequency of different signal components fluctuated at the different stages of tool wear and at different cutting conditions, the frequency of vibration components was always within a band of 98–40 kHz, and the AE has varied between 51 kHz and 620 kHz.     

Asymmetric surface roughness measurements and meniscus modeling of polysilicon surface micromachined flaps

Polycrystalline silicon (polysilicon) films are primary structural materials for microelectromechanical systems (MEMS). Due to relatively high compliance, large surface-to-volume ratio, and small separation distances, micromachined polysilicon structures are susceptible to surface forces which can result in adhesive failures. Since these forces depend on surface properties especially surface roughness, three types of microhinged flaps were fabricated to characterize their roughness and adhesive meniscus properties. The flaps enabled access to both the top and bottom surfaces of the structural polysilicon layers. Roughness measurements using an atomic force microscope revealed that MEMS surfaces primarily exhibit non-Gaussian surface height distributions, and for the release procedures studied, the bottom surface of the structural layers was significantly smoother and prone to higher adhesion compared to the top surface. A non-symmetric surface roughness model using the Pearson system of frequency curves was coupled with a capillary meniscus adhesion model to analyze the effects of surface roughness parameters (root-mean-square, skewness, and kurtosis), relative humidity, and surface contact angle on the interfacial adhesion energy. Using the measured roughness properties of the flaps, four different surface pairs were simulated and compared to investigate their effects on capillary adhesion. It was found that since the base polysilicon layer (poly0) was rougher than the base silicon nitride and the structural layer on poly0 was also rougher than that on silicon nitride, depositing MEMS devices on poly0 layer rather than directly on silicon nitride will reduce the adhesion energy.     

Removal of transient disturbances from oscillating measurements using nearest neighbors imputation

Transient disturbances in process measurements compromise the accuracy of some methods for plant-wide oscillation analysis. This paper presents a method to remove such transients while maintaining the dynamic features of the original measurement. The method is based on a nearest neighbors imputation technique. It replaces the removed transient with an estimate which is based on the time series of the whole measurement. The method is demonstrated on experimental and industrial case studies. The results demonstrate the efficacy of the method and recommended parameters. Furthermore, inconsistency indices are proposed which facilitate the automation of the method.     

Zigzag machining surface roughness modelling using evolutionary approach

Milling is one of the common machining methods that cannot be abandoned especially for machining of metallic materials. The cutters with appropriate cutting parameters remove material from the workpiece. Surface roughness has the major influence on both obtaining dimensional accuracy and quality of the product. A number of cutter path strategies are employed to obtain the required surface quality. Zigzag machining is one of the mostly appealing cutting processes. Modeling of surface roughness with traditional methods often results in inadequate solutions and can be very costly in terms of the efforts and the time spent. In this research Genetic Programming (GP) has employed to predict a surface roughness model based on the experimental data. The model has produced an accuracy of 86.43%. In order to compare GP performance, Artificial Neural Network (ANN) and Adaptive Neuro Fuzzy Inference System (ANFIS) techniques were utilized. It was seen that the surface roughness model produced by GP not only outperforms but also enables to produce more explicit models than of the other techniques. The effective parameters can easily be investigated based on the appearances in the model and they can be used in prediction of surface roughness in zigzag machining process.     

High relative humidity measurements using gelatin coated long-period grating sensors

A long-period grating (LPG) coated with gelatin was developed as a high relative humidity (RH) sensor. The resonance dip or coupling strength of the LPG spectrum varies with RH. Experimental investigations on the sensor yield a sensitivity of 0.833%RH/dB with an accuracy of ±0.25%RH, and a resolution of ±0.00833%RH. The LPG RH sensor also offers repeatability, hysteresis and stability errors of less than ±0.877, ±0.203 and ±0.04%RH, respectively. In addition to the characterization of the LPG RH sensor, further studies were conducted to determine the effect of grating periodicities on the sensitivity of the sensor. Results show that higher order cladding modes from smaller grating periods enable the sensor to achieve higher sensitivity to humidity. This method is proposed to be more cost effective as compared to more complex spectroscopic methods based on wavelength detection. This sensor can also help to solve problems in measuring high humidity with existing relative humidity measurement systems.     

Effect of surface roughness,wavelength, illumination,and viewing zenith angles on soil surface BRDF using an imaging BRDF approach

Compared to non-imaging instruments, imaging spectrometers (ISs) can provide detailed information to investigate the influence of scene components on the bidirectional reflectance distribution function (BRDF) of a mixed target. The research reported in this article investigated soil surface reflectance changes as a function of scene components (i.e. illuminated pixels and shaded pixels), illumination and viewing zenith angles, and wavelength. Image-based BRDF data of both rough and smooth soil surfaces were acquired in a laboratory setting at three different illumination zenith angles and at four different viewing zenith angles over the full 360° azimuth range, at an interval of 20°, using a Specim V10E IS (Specim, Spectral Imaging Ltd., Oulu, Finland) mounted on the University of Lethbridge Goniometer System version 2.5 (ULGS-2.5). The BRDF of the smooth soil surface was dominated by illuminated pixels, whereas the shaded pixels were a larger component of the BRDF of the rough soil surface. As the illumination zenith angle was changed from 60° to 45° and then to 30°, the shadowing effect decreased, regardless of the soil surface. Soil surface reflectance was generally higher at the backscattering view zenith angles and decreased continuously to forward scattering view zenith angles in the light principal plane, regardless of the wavelength, due to the Specim V10E IS seeing more illuminated pixels in the backscattering angles than in the forward scattering angles. Higher soil surface reflectance was observed at higher illumination and viewing zenith angle combinations. For both soil surface roughness categories, the BRDF exhibited a greater range of values in the near-infrared than at the visible wavelengths. This research enhances our understanding of soil BRDF for various soil roughness and illumination conditions.     

Effect of tool vibrations on surface roughness during lathe dry turning process

Choice of optimized cutting parameters is very important to control the required surface quality. In fact, the difference between the real and theoretical surface roughness can be attributed to the influence of physical and dynamic phenomena such as: built-up edge, friction of cut surface against tool point and vibrations. The focus of this study is the collection and analysis of surface roughness and tool vibration data generated by lathe dry turning of mild carbon steel samples at different levels of speed, feed, depth of cut, tool nose radius, tool length and work piece length. A full factorial experimental design (288 experiments ) that allows to consider the three-level interactions between the independant variables has been conducted. Vibration analysis has revealed that the dynamic force, related to the chip-thickness variation acting on the tool, is related to the amplitude of tool vibration at resonance and to the variation of the tool's natural frequency while cutting. The analogy of the effect of cutting parameters between tool dynamic forces and surface roughness is also investigated. The results show that second order interactions between cutting speed and tool nose radius, along with third-order interaction between feed rate, cutting speed and depth of cut are the factors with the greatest influence on surface roughness and tool dynamic forces in this type of operation and parameter levels studied. The analysis of variance revealed that the best surface roughness condition is achieved at a low feed rate (less than 0.35 mnt/rev), a large tool nose radius (1.59 mm) and a high cutting speed (265 m/min and above). The results also show that the depth of cut has not a significant effect on surface roughness, except when operating within the built-up edge range. It is shown that a correlation between surface roughness and tool dynamic force exist only when operating in the built-up edge range. In these cases, built-u edge formation deteriorates surface roughness and increases dynamic forces acting on the tool. The effect of built-up edge formation on surface roughness can be minimized by increasing depth of cut and increasing tool vibration. Key words:design of experiments, lathe dry turning operation, full factorial design, surface roughness, measurements, cutting parameters, tool vibrations.     

Surface roughness effects on the oscillating squeeze-film behavior of long partial journal bearings

The surface roughness effects on the pure squeeze-film behavior of a long partial journal bearing operating under a time-dependent oscillating load is analyzed. Based upon the Christensen's stochastic model, the stochastic Reynolds-type equation governing the film pressure is derived to take account of the presence of roughness on bearing surfaces. The nonlinear equation of squeezing motion is then formulated by applying the hydrodynamic film force. According to the results evaluated, the mean squeeze-film characteristics are significantly affected by the roughness pattern and the height of roughness. The effect of circumferential roughness provides a reduction in the mean bearing eccentricity ratio as compared to the smooth-bearing case. However, the squeeze-film bearing with longitudinal roughness structure results in a reversed trend. Furthermore, the quantitative effects of surface roughness on the oscillating squeeze-film characteristics are more pronounced for small values of Sommerfeld number and large values of roughness parameter.     

Minimal roughness property of the Delaunay triangulation

A set of scattered data in the plane consists of function values measured on a set of data points in R². A surface model of this set may be obtained by triangulating the set of data points and constructing the Piecewise Linear Interpolating Surface (PLIS) to the given function values. The PLIS is combined of planar triangular facets with vertices at the data points. The roughness measure of a PLIS is the L² norm squared of the gradient of the piecewise linear surface, integrated over the triangulated region and obviously depends on the specific triangulation. In this paper we prove that the Delaunay triangulation of the data points minimizes the roughness measure of a PLIS, for any fixed set of function values. This Theorem connects for the first time, as far as we know, the geometry of the Delaunay triangulation with the properties of the PLIS defined over it.     

表面粗糙度光学测量方法研究进展

表面粗糙度对工件的性能有很大的影响,由于机械、电子及光学工业的飞速发展,对精密机械加工表面的质量及结构小型化的要求日益提高,使得表面粗糙度测量显现出越来越重要的地位。采用光学方法测量表面粗糙度具有非接触、无损伤、测量精度高等优点。介绍了用光散射法、像散法、散斑法、光干涉法、光学触针法测量表面粗糙度的原理及研究进展,讨论了上述方法各自的优缺点,对表面粗糙度测量的发展方向进行了预测。     

用VBA在AutoCAD中添加标注表面粗糙度专用命令的方法

介绍了应用Ｖｉｓｕａｌ Ｂａｓｉｃ Ａｐｐｌｉｃａｔｉｏｎ语言在ＡｕｔｏＣＡＤ中添加标注表面粗糙度专用命令的方法，给出了具体的编程步骤。     

Chemical gas sensors using chiral nematic liquid crystals and its applications

This paper clarifies the relationship between the molecular structures of chiral nematic liquid crystals and the shift in their reflection spectrum resulting from contact with volatile organic compounds (VOCs). We also propose a mechanism to explain the red‐ or blue‐shift in the peak wavelength upon contact with VOC vapor. Furthermore, enhancement of the sensitivity of this method of VOC detection is discussed.     

Surface exploration using laparoscopic surgical instruments: The perception of surface roughness

During laparoscopic surgery video images are used to guide the movements of the hand and instruments, and objects in the operating field often obscure these images. Thus, surgeons often rely heavily on tactile information (sense of touch) to help guide their movements. It is important to understand how tactile perception is affected when using laparoscopic instruments, since many surgical judgements are based on how a tissue ‘feels’ to the surgeon, particularly in situations where visual inputs are degraded. Twelve naïve participants used either their index finger or a laparoscopic instrument to explore sandpaper surfaces of various grits (60, 100, 150 and 220). These movements were generated with either vision or no vision. Participants were asked to estimate the roughness of the surfaces they explored. The normal and tangential forces of either the finger or instrument on the sandpaper surfaces were measured. Results showed that participants were able to judge the roughness of the sandpaper surfaces when using both the finger and the instrument. However, post hoc comparisons showed that perceptual judgements of surface texture were altered in the no vision condition compared to the vision condition. This was also the case when using the instrument, compared to the judgements provided when exploring with the finger. This highlights the importance of the completeness of the video images during laparoscopic surgery. More normal and tangential force was used when exploring the surfaces with the finger as opposed to the instrument. This was probably an attempt to increase the contact area of the fingertip to maximize tactile input. With the instrument, texture was probably sensed through vibrations of the instrument in the hand. Applications of the findings lie in the field of laparoscopic surgery simulation techniques and tactile perception.     

Surface exploration using laparoscopic surgical instruments: the perception of surface roughness

During laparoscopic surgery video images are used to guide the movements of the hand and instruments, and objects in the operating field often obscure these images. Thus, surgeons often rely heavily on tactile information (sense of touch) to help guide their movements. It is important to understand how tactile perception is affected when using laparoscopic instruments, since many surgical judgements are based on how a tissue 'feels' to the surgeon, particularly in situations where visual inputs are degraded. Twelve na?ve participants used either their index finger or a laparoscopic instrument to explore sandpaper surfaces of various grits (60, 100, 150 and 220). These movements were generated with either vision or no vision. Participants were asked to estimate the roughness of the surfaces they explored. The normal and tangential forces of either the finger or instrument on the sandpaper surfaces were measured. Results showed that participants were able to judge the roughness of the sandpaper surfaces when using both the finger and the instrument. However, post hoc comparisons showed that perceptual judgements of surface texture were altered in the no vision condition compared to the vision condition. This was also the case when using the instrument, compared to the judgements provided when exploring with the finger. This highlights the importance of the completeness of the video images during laparoscopic surgery. More normal and tangential force was used when exploring the surfaces with the finger as opposed to the instrument. This was probably an attempt to increase the contact area of the fingertip to maximize tactile input. With the instrument, texture was probably sensed through vibrations of the instrument in the hand. Applications of the findings lie in the field of laparoscopic surgery simulation techniques and tactile perception.     

Least-squares linear estimators using measurements transmitted by different sensors with packet dropouts

The least-squares linear estimation problem (including prediction, filtering and fixed-point smoothing) from measurements transmitted by different sensors subject to random packet dropouts is addressed. For each sensor, a different Bernoulli sequence is used to model the packet dropout process. Under the assumption that the signal evolution model is unknown, recursive estimation algorithms are derived by an innovation approach, requiring only information about the covariances of the processes involved in the observation equation, as well as the knowledge of the dropout probabilities at each sensor.     

Estimation of cutting forces and surface roughness for hard turning using neural networks

Metal cutting mechanics is quite complicated and it is very difficult to develop a comprehensive model which involves all cutting parameters affecting machining variables. In this study, machining variables such as cutting forces and surface roughness are measured during turning at different cutting parameters such as approaching angle, speed, feed and depth of cut. The data obtained by experimentation is analyzed and used to construct model using neural networks. The model obtained is then tested with the experimental data and results are indicated.     

Interrogation of surface plasmon resonance sensors using temporally stretched ultrashort optical pulses

We propose a novel technique that has the potential to realize interrogation of surface plasmon resonance (SPR) sensors at very high speed. In contrast to the incoherent light source used in the traditional wavelength interrogation schemes, a broadband coherent laser generating short optical pulses at a high repetition rate is used along with a highly dispersive optical element. The dispersion causes strong broadening of the optical pulses, and the temporal pulse shape could exactly resemble the spectral distribution of the pulses due to the induced linear chirp. Therefore, by measuring the changes in the pulse shapes with a single high-speed photodetector, the spectral response of the SPR sensor can be obtained for each input pulse and the interrogation speed could reach the repetition rate of the pulse train. This could enable SPR measurements at the speed of tens of MHz or higher, which is well beyond that of other current SPR interrogation techniques. We experimentally demonstrate that, by measuring the variations in the pulse shapes of the chirped pulses, sensitive SPR measurements can be made. Implementing this scheme with a femtosecond fiber laser and other fiber optic components also show the potential to realize more compact and integrated SPR systems.     

Homeotropic alignment of liquid crystals on ITO surface using LBL assembly

In this work, the very thin layer‐by‐layer (LBL) film that was constructed by dip coating method on indium tin oxide surface can be used in liquid crystal (LC) displays devices. The obtained results indicate that the ultrathin LBL film shows the homeotropic alignment layer, and a uniform vertical alignment of LC molecules was gained very easily. The progress of vertical‐aligned LC cells with a LBL layer was evaluated. The obtained threshold voltage and response time of the LC cell were 2.472 V and 12.5 ms, respectively. So, the competitive performance of the LC cell could allow new sign at a low‐cost budget with rubbing process in LC display technology.     

Influence of soil surface roughness on soil bidirectional reflectance

The non-Lambertian behaviour of soil surfaces depends on its roughness at micro-scale and larger scales, as well as on the incident angle of the direct solar beam on the surface. A geometrical model, taking into account the diffuse as well as the specular component of energy leaving soil surfaces in the visible and near-infrared, is used in the paper to describe the influence of soil surface roughness, caused by soil aggregates or soil clods, on the soil bidirectional reflectance distribution. A rough soil surface in the model is simulated by equalsized opaque spheroids lying on a horizontal surface. The model was tested in outdoor conditions on artificially formed soil surfaces made of two spectrally different soil materials: a mineral loam, and a loam with high organic matter content. The spectral data were measured by a field radiometer in the three SPOT (HRV) bands. The model predicts that at specific illumination conditions, soils surfaces with the highest roughness, expressed by the minimum distances between soil aggregates, can show lower variation of reflectance in the view zenith angle function than soil surfaces of a lower roughness.