Automated Surface Inspection Using Gabor Filters

In this paper we present a machine vision system for the automatic inspection of defects in textured surfaces found in industry. The defects to be inspected are those that appear as local anomalies embedded in a homogeneous texture. The proposed method is based on a Gabor filtering scheme that computes the output response of energy from the convolution of a textured image with a specific Gabor filter. The best parameters of a Gabor filter are selected so that the energy of the homogeneous texture is zero, and any unpredictable defeats will generate significantly large energy values. A simple thresholding scheme then follows to discriminate between homogeneous regions and defective regions in the filtered image. This transforms texture differences into detectable filter output. The experiments on structural textures such as leather and sandpaper have shown the effectiveness of the proposed method.     

Automatic surface inspection for directional textures using nonnegative matrix factorization

A global image restoration scheme using nonnegative matrix factorization (NMF) is proposed in this paper. This NMF-based image restoration scheme can be used for inspecting the defects in directional texture surfaces automatically. Decomposing the gray level of image pixels into an ensemble of row vectors, we first reduce the data set from original data space into a lower-dimensional NMF space. The repetitive and periodical primitives are well reconstructed by two lower-dimensional basis and weight matrices with nonnegative elements, named nonnegative matrix approximation (NMA). Then the local defects will be revealed by applying image subtraction between the original image and the NMA. As a consequence, the directional textures are eliminated, and only local defects are preserved if they initially are embedded in the surface. A supervised heuristic, elbow of residual curve rule, is devised which helps users to determine a proper basis space size of a specific image. Experiments on a variety of directional texture surfaces are given to demonstrate the effectiveness and robustness of the proposed method.     

Detection of pinhole defects on chips and wafers using DCT enhancement in computer vision systems

This paper presents a global approach for the automatic inspection of tiny pinhole defects in randomly textured surfaces of surface barrier layer (SBL) chips. By means of a discrete cosine transform (DCT)-based image restoration scheme, the proposed method is independent of textural features and thus not confined by the limitations of feature extraction based methods. Through properly decomposing the frequency matrix of an image in the DCT domain and selecting the best radius of the sector filter for the high-pass filtering operation, we effectively attenuate the global random texture pattern and accentuate only tiny pinhole defects in the restored image. We also develop two accumulative sum detection procedures that automatically determine the best high-pass filtering parameters based on the abrupt changes of the frequency coefficients in the decomposed matrix. Experimental results show that the proposed method outperforms the traditional approach in reducing the Type I error by 70–80% and in decreasing the deviation of the defect areas by 95%. Moreover, the proposed method can be applied to various types of passive components in large-batch production because no precise positioning of the target chip or template matching is required.     

Fast Defect Detection in Textured Surfaces Using 1D Gabor Filters

In this paper, we present a fast machine vision method for the automatic inspection of defects in textured surfaces. Traditional 2D Gabor filtering schemes have been shown to be very effective for detecting local anomalies in textured surfaces of industrial materials. However, they are computationally expensive and sensitive to image rotation. In order to alleviate the limitations of 2D Gabor filtering, we first use a 1D ring-projection transformation to compress a 2D grey-level image into a 1D pattern, and then employ a 1D Gabor filter to detect defects embedded in a homogeneous texture. Given a problem with image size N × N and filter window W × W, the computational complexity can be reduced significantly from O(W ² N ² ) in the 2D Gabor space to O(WN ² ) in the 1D Gabor space, and the detection results are invariant to rotation changes of a texture. The experiments on structural textures such as a wooden surface, an LCD display, and a machined surface, and statistical textures such as granite, leather, and sandpaper have shown the efficiency and effectiveness of the proposed method. ID="A1" Correspondence and offprint requests to: Dr Du-Ming Tsai, Department of Industrial Engineering and Management, Yuan-Ze University, 135 Yuan-Tung Road, Nei-Li, Tao-Yuan, Taiwan. E-mail: iedmtsai@saturn.yzu.edu.tw     

Creating machinable textures for CAD/CAM systems

Texture is applied on three-dimensionally modelled surfaces in computer graphics to enhance visual effect. This research focuses on the development of three-dimensional textured surfaces which are suitable for manufacturing. Three approaches for creating the three-dimensional texture are presented.The first approach is to process a design from either an artist's sketch or an image from a two-dimensional scan. The second approach uses a three-dimensional scanned texture. Both these approaches depend on the quality of the scanned image and are more tedious than the third approach, which is to convert texture using parameters and is a more direct approach. In the user interface design, two custom-made forms are developed to cater for both regular and irregular textures.The case studies have shown that the textures created are not only good for a visual effect, but are also machinable. The development work is incorporated into the ArtCAM system which is a specialised CAD/CAM system that is capable of generating three-dimensional shapes from two-dimensional artwork.     

Multiscale analysis on two-dimensional nanoscale adhesive contacts

Nanoscale adhesive contacts play a key role in micro/nano-electro-mechanical systems as the dimension of the components come to nanometer.Experimental studies on nanoscale adhesive contacts are limited by some uncertain factors and the cost of experiments is too high.Besides,nanoscale textured surfaces are difficult to process and nanoscale adhesive contacts of textured surfaces are still lack of investigation.By using multiscale method,which couples molecular dynamics simulation and finite element method,two-dimensional nanoscale adhesive contacts between a rigid cylindrical tip and an elastic substrate are investigated.For the contacts between the rigid cylindrical tip and smooth surface,Von Mises stress distributions,the maximum Von Mises stresses,and contact forces are compared for different radii to show the size effects and adhesive effects.The phenomena of hysteresis are observed and more obvious as the radii of the tip increase.The influences of indentation depth and indentation speed are also discussed.Then two series of textured surfaces are employed,and the influences of the texture asperity shape,asperity height,and asperity spacing on contact forces are studied.The contact forces comparisons show that textured surfaces can reduce contact forces effectively in the range of the two series.Contact forces of textured surfaces increase as the asperity heights increase,and textured surfaces with smaller asperity spacing will get higher contact forces.Contact forces may be controlled through textured surfaces in the future.The obtained results will help to improve contact condition and provide theory basis for texture design.     

Crater and flank wear resistance of cutting tools having micro textured surfaces

We have proposed cutting tools with various textured surfaces to increase cutting tool life. Our previous studies have developed cutting tools having periodical stripe-grooved surfaces on their rake face formed using femtosecond laser technology, which displayed high crater wear resistance in cutting of steel materials. In this study, the mechanism for suppressing the crater wear on the tool surface and the relationship between texture dimensions and wear resistance were investigated to provide a guideline for developing tools with textured surfaces. Furthermore, we newly introduced the textured surfaces into a flank face of cutting tools to improve flank wear resistance. Face milling experiments on steel materials exhibited that the newly developed tool having the textured flank face significantly reduced the flank wear. Moreover, the influences of texture dimensions and cutting conditions on the flank wear resistance were also discussed.     

Directional textures auto-inspection using principal component analysis

This paper describes a global image restoration scheme using a principal component analysis that can be used to inspect defects in directional textured surfaces automatically. Decomposing the gray level of image pixels into an ensemble of row vectors, the input spatial domain image is transformed into principal component space so that the directional textures are well approximated by first k major components and their corresponding weight vectors, named truncated component solution (TCS). Then the local defects will be revealed by applying image subtraction between the original image and the TCS. This procedure blurs all directional textures and preserves only the local defects that were initially embedded in the input image. These defects, if any, are finally extracted by thresholding. Experiments on a variety of product surfaces with directional textures such as straight, slanted, orthogonal, slanted orthogonal, and oblique linear primitives were conducted to demonstrate the effectiveness and robustness of the proposed method. Furthermore, some preliminary experiments were also conducted to demonstrate the proposed scheme was insensitive to horizontal and vertical shifting, changes in illumination, and image rotation.     

Frictional and load‐carrying behaviours of micro‐textured sector shape pad thrust bearing incorporating the cavitation and thermal effects

Frictional and load‐carrying behaviours of micro‐textured sector shape pad thrust bearing have been explored and reported herein. The textured pad surfaces have been generated employing different cross‐sectional shapes (circular, square, trapezoidal and triangular) of grooves. Based on the thermohydrodynamic lubrication analysis, it is observed that when the adopted texture pattern is placed on the pad towards the entry region, it produces substantial reduction in friction coefficient. The texture involving the square cross‐sectional shape of grooves has yielded substantial reductions in the friction coefficient in comparison with the conventional plain pad. Copyright © 2016 John Wiley & Sons, Ltd.     

Fabrication of 3D submicron to micro textured surfaces using backside patterned texturing (BPT)

This work presents a novel fabrication method for submicron to micro size textures on flat surfaces using the backside patterned texturing (BPT). The proposed method utilizes the pre-fabricated macro-features on the backside of work material, and thereafter the front side is face turned with a single point diamond tool to generate textured surfaces. Different from existing texturing methods, BPT produces textured surfaces from submicron to micro scale without any external gadgets such as vibration assisted machining or synchronized tool-spindle motion. The miniature feature arises on the diamond turned surface due to the induced residual stresses when the specimen is unleashed from the machine. To demonstrate the efficacy of the method, a series of machining experiments were conducted to fabricate various types of freeform surface textures like water-drop freeform, cylindrical freeform surfaces, etc. The fabrication methodology of different sizes of bumps with precisely controlled surface quality is illustrated. The texture profiles comprising the deformation height from hundreds of nanometer to few micrometers with mirror surface quality were successfully fabricated on the diamond machined surface. The experimental results suggest that the pre-fabricated pattern, workpiece thickness and machining condition play a critical role to determine the final shape and geometry of generated textures.     

Two dimensional nanoscale reciprocating sliding contacts of textured surfaces

Detailed behaviors of nanoscale textured surfaces during the reciprocating sliding contacts are still unknown although they are widely used in mechanical components to improve tribological characteristics. The current research of sliding contacts of textured surfaces mainly focuses on the experimental studies, while the cost is too high. Molecular dynamics(MD) simulation is widely used in the studies of nanoscale single-pass sliding contacts, but the CPU cost of MD simulation is also too high to simulate the reciprocating sliding contacts. In this paper, employing multiscale method which couples molecular dynamics simulation and finite element method, two dimensional nanoscale reciprocating sliding contacts of textured surfaces are investigated. Four textured surfaces with different texture shapes are designed, and a rigid cylindrical tip is used to slide on these textured surfaces. For different textured surfaces, average potential energies and average friction forces of the corresponding sliding processes are analyzed. The analyzing results show that “running-in” stages are different for each texture, and steady friction processes are discovered for textured surfaces II, III and IV. Texture shape and sliding direction play important roles in reciprocating sliding contacts, which influence average friction forces greatly. This research can help to design textured surfaces to improve tribological behaviors in nanoscale reciprocating sliding contacts.     

基于ABAQUS的表面微织构刀具切削钛合金仿真研究

利用有限元软件ABAQUS构建钛合金切削过程的二维仿真模型,通过钛合金切削试验验证模型的正确性。对微织构刀具切削钛合金的过程进行仿真,与无微织构刀具切削钛合金的仿真进行对比分析,研究了微织构刀具应力分布、切削力的变化规律以及对等效塑性应变的影响。仿真研究表明,微织构的存在对切削过程中刀具的应力分布有积极的改善作用,可以降低切削力,减少塑性应变。     

Surface texture generation using high-feed milling with spindle speed modulation

This paper presents a new surface texturing technique using ball-end milling with high feed speed and spindle speed modulation. The ratio between feed-rate and cutting tool radius is in the range of 0.2–0.4, which is much larger than the ratio in conventional milling. Sinusoidal modulation signal is added, so the spindle speed becomes time-varying in order to generate different texture profiles. The cutting tool kinematics are modeled considering the tool-tip run-out and deflection due to cutting forces. The effects of amplitude and frequency of the modulation signal on tool-tip trajectories and surface textures are simulated and analyzed. The relationship between the micro features of the surface texture and the process parameters are investigated. Surface texturing experiments are conducted based on the proposed technique, and tribology tests are performed on the textured surface. It is shown that the textured surfaces present frictional anisotropy, which depends on the process conditions and modulation parameters. The proposed technique is able to achieve fast generation of various surface textures without additional instrumentation, and the final texture geometry is controllable based on the presented kinematics model.     

一种大尺寸双冗余机载液晶显示器的设计

为了满足现代化大尺寸机载液晶显示器环境适应性以及可靠性的要求,采用了一体化大屏设计思想、双冗余设计方法以及特殊加固工艺技术,建立抗振动、冲击模型以及热力学仿真模型,通过ANSYS和FloTHERM仿真软件,获得机载液晶显示器各组件的应力分布以及温度分布情况。做了高低温、振动、冲击、湿热以及霉菌等国军标要求的相关实验后,得到机载液晶显示器抗振动、冲击以及热设计的重要方法和参考数据,并结合双冗余设计方法,使大尺寸机载液晶显示器能够满足军事领域使用要求。     

人工髋关节球形凹坑微织构表面摩擦学性能研究*

为改善人工髋关节表面的摩擦学性能,在人工髋关节表面设计球形凹坑微织构;建立人工髋关节微织构表面的流体动压润滑模型,利用CFD软件ANSYS Fluent对微织构表面流体动压进行数值分析,得到摩擦副表面相对滑动时产生的油膜平均承载力以及摩擦因数,并分析表面微织构参数对摩擦学性能的影响。结果表明:在给定的织构参数范围内,平均承载力随深径比的增加呈现出先降低后升高再降低的趋势,随面积密度的增加呈先升高再降低的趋势;摩擦因数随深径比和面积密度增加的变化趋势与平均承载力相反;织构的最优参数分别为深径比0.06,面积密度25%。因此,在人工髋关节表面设置合适参数的球形凹坑微织构可以提高油膜平均承载力和降低摩擦因数,从而起到减小关节的摩擦磨损提高人工关节使用寿命的作用。     

水压马达配流副椭圆形织构表面流场分析*

为了探究椭圆形织构化表面对水压马达配流副流体动压润滑性能的影响,构建椭圆形织构配流副表面的全水动压润滑模型,采用CFD的方法分析在不同尺寸、不同面积率条件下,两旋转表面摩擦润滑性能的变化规律。结果表明：不同尺寸的椭圆形织构表面均能产生良好的流体动压润滑性能;不同尺寸椭圆形织构的水膜承载力随面积率的变化呈现出不同的变化规律,但相同尺寸的织构表面随面积率的变化呈现出相同的变化规律,且转速越大,规律性越明显;在相同面积率下,转速越高,织构的水膜承载力越强;不同尺寸椭圆形织构在各自最优面积率下的水膜承载力不同,其中长轴、短轴分别为1.6、0.8 mm的椭圆形织构表现出最优的水膜承载性能。     

基于 STFT 的织构涂层硬质合金表面振动解析方法

针对织构涂层复合工艺对硬质合金表面改性时存在消极振动的问题,提出一种基于织构涂层表面摩擦振动行为的解析 方法来探索织构涂层复合工艺改性效果。 因此,搭建了微织构 AlSiTiN 涂层硬质合金-钛合金磨盘摩擦磨损试验平台,基于短 时傅里叶变换(STFT)与灰度算法对摩擦振动变化规律性映射和振动行为平稳时段进行了获取,进而分析了微织构 AlSiTiN 涂 层工艺参数对硬质合金的改性效果。 试验研究得出了微织构及 AlSiTiN 涂层对硬质合金表面耐磨改性效果最为积极的时间 段,即自接触摩擦起第 5~ 25 min 的稳定作用时期,得出微织构及 AlSiTiN 涂层参数对硬质合金表面改性的影响机理,优选该复 合改性方法抑制硬质合金表面消极摩擦振动的工艺参数,为提升硬质合金表面性能研究提供新思路。     

Effect of textured area on the performances of a hydrodynamic journal bearing

A growing interest is given to the textured hydrodynamic lubricated contacts. The use of textured surfaces with different shapes of microcavities (textures) and at different locations of the texture zone can be an effective approach to improve the performance of bearings. The present study examines the texture location influence on the hydrodynamic journal bearing performance. A numerical modelling is used to analyze the cylindrical texture shape effect on the characteristics of a hydrodynamic journal bearing. The theoretical results show that the most important characteristics can be improved through an appropriate arrangement of the textured area on the contact surface.     

复合工艺制备的表面微凹坑织构的摩擦性能研究

在构建的激光电化学复合微加工系统上,采用皮秒脉冲激光辐照与电解刻蚀复合加工方法在7075铝合金表面制备出不同尺寸的阵列凹坑微织构。采用共聚焦显微镜观测复合加工织构试样表面形貌,采用MFT-5000型RTEC摩擦磨损试验机研究润滑条件下凹坑织构的摩擦学性能,并探讨直径、深度、面积密度对减摩性能的影响。结果表明:复合加工工艺制备的表面微织构具有良好的表面形貌;润滑条件下材料表面的凹坑型织构能显著改善其摩擦学性能,相比光滑表面最高可降低摩擦因数30%;在实验参数范围内,凹坑的直径与面积密度对材料表面摩擦性能影响较大,凹坑深度对摩擦性能影响较小。     

界面滑移对圆柱形凹坑织构滑动轴承摩擦力的影响

为研究不同的滑移情况对圆柱形凹坑织构滑动轴承摩擦力的影响,建立含有圆柱形凹坑织构的滑动轴承在不同界面滑移状态下的摩擦力计算模型,探究影响织构化滑动轴承摩擦力的参数,并借助ANSYS分析不同滑移情况下界面滑移对圆柱形凹坑织构滑动轴承摩擦力的影响规律。结果表明:织构化滑动轴承的摩擦力主要是由轴颈线速度、油膜滑移比、轴承的进出油口压力、织构处油膜压力、织构深度、油膜厚度和承载力决定;不同滑移情况下织构模型的摩擦力均小于无织构模型;且在上下表面均滑移时,圆柱形凹坑织构在出口位置时表现出最优的承载和减摩效果;适当地增加圆柱形凹坑织构的深度可以改善模型的摩擦性能,但是过深的凹坑织构并不能发挥出其性能。