In this paper, an experimental surface roughness analysis in milling of tungsten carbide using a monolithic torus cubic boron nitride (CBN) tool is presented. The tungsten carbide was received using direct laser deposition technology (DLD). The depth of cut (ap), feed per tooth (fz) and tool wear (VBc) influence on surface roughness parameters (Ra, Rz) were investigated. The cutting forces and accelerations of vibrations were measured in order to estimate their quantitative influence on Ra and Rz parameters. The surface roughness analysis, from the point of view of milling dynamics was carried out. The dominative factor in the research was not feed per tooth fz (according to a theoretical model) but dynamical phenomena and feed per revolution f connected with them.

The paper presents the results of investigations of the growth of protective coating on the surface of ductile iron casting during the hot-dip

galvanizing treatment. Ductile iron of the EN-GJS-600-3 grade was melted and two moulds made by different technologies were poured to

obtain castings with different surface roughness parameters. After the determination of surface roughness, the hot-dip galvanizing

treatment was carried out. Based on the results of investigations, the effect of casting surface roughness on the kinetics of the zinc coating

growth was evaluated. It was found that surface roughness exerts an important effect on the thickness of produced zinc coating

Surface roughness parameter prediction and evaluation are important factors in determining the satisfactory performance of machined surfaces in many fields. The recent trend towards the measurement and evaluation of surface roughness has led to renewed interest in the use of newly developed non-contact sensors. In the present work, an attempt has been made to measure the surface roughness parameter of different machined surfaces using a high sensitivity capacitive sensor. A capacitive response model is proposed to predict theoretical average capacitive surface roughness and compare it with the capacitive sensor measurement results. The measurements were carried out for 18 specimens using the proposed capacitive-sensor-based non-contact measurement setup. The results show that surface roughness values measured using a sensor well agree with the model output. For ground and milled surfaces, the correlation coefficients obtained are high, while for the surfaces generated by shaping, the correlation coefficient is low. It is observed that the sensor can effectively assess the fine and moderate rough-machined surfaces compared to rough surfaces generated by a shaping process. Furthermore, a linear regression model is proposed to predict the surface roughness from the measured average capacitive roughness. It can be further used in on-machine measurement, on-line monitoring and control of surface roughness in the machine tool environment.

The prediction of machined surface parameters is an important factor in machining centre development. There is a great need to elaborate a method for on-line surface roughness estimation [1-7]. Among various measurement techniques, optical methods are considered suitable for in-process measurement of machined surface roughness. These techniques are non-contact, fast, flexible and tree-dimensional in nature.

The optical method suggested in this paper is based on the vision system created to acquire an image of the machined surface during the cutting process. The acquired image is analyzed to correlate its parameters with surface parameters. In the application of machined surface image analysis, the wavelet methods were introduced. A digital image of a machined surface was described using the one-dimensional Digital Wavelet Transform with the basic wavelet as Coiflet. The statistical description of wavelet components made it possible to develop the quality measure and correlate it with surface roughness [8-11].

For an estimation of surface roughness a neural network estimator was applied [12-16]. The estimator was built to work in a recurrent way. The current value of the Ra estimation and the measured change in surface image features were used for forecasting the surface roughness Ra parameter. The results of the analysis confirmed the usability of the application of the proposed method in systems for surface roughness monitoring.

A numerical solution is presented to investigate the influence of the geometry and the amplitude of the transverse ridge on the characteristics of elastohydrodynamic lubrication for point contact problem under steady state condition. Several shapes of ridges with different amplitudes are used in the stationary case, such as flattop ridge, cosine wave ridge and sharp ridge of triangular shape. Results of film thickness and pressure distributions of the aforementioned ridge feature are presented at different locations through an elastohydrodynamically lubricated contact zone for different amplitude of the ridge. Simulations were performed using the Newton-Raphson iteration technique to solve the Reynolds equation. The numerical results reveal that, to predict optimum solution for lubricated contact problem with artificial surface roughness, the geometrical characteristics of the ridge should have profiles with smooth transitions such as those of a cosine wave shape with relatively low amplitude to reduce pressure spike and therefore cause the reduction in the film thickness. The position of the location of the ridge across the contact zone and the amplitude of the ridge play an important role in the formation of lubricant film thickness and therefore determine the pressure distribution through the contact zone.

In this paper, the authors present surface roughness profile assessment using continuous wavelet transform (CWT). Roughness profiles after turning and rough and finish belt grinding of hardened (62HRC) AISI 52100 steel are analyzed. Both Morlet and “Mexican hat” analyzing wavelets are used for the assessment of extrema and frequency distribution. The results of the CWT as a function of profile and momentary wavelet length are presented. It is concluded that CWT can be useful for the analysis of the roughness profiles generated by cutting and abrasive machining processes.

This paper explores the parametric appraisal and machining performance optimization during drilling of polymer nanocomposites reinforced by graphene oxide/carbon fiber. The consequences of drilling parameters like cutting velocity, feed, and weight % of graphene oxide on machining responses, namely surface roughness, thrust force, torque, delamination (In/Out) has been investigated. An integrated approach of a Combined Quality Loss concept, Weighted Principal Component Analysis (WPCA), and Taguchi theory is proposed for the evaluation of drilling efficiency. Response surface methodology was employed for drilling of samples using the titanium aluminum nitride tool. WPCA is used for aggregation of multi-response into a single objective function. Analysis of variance reveals that cutting velocity is the most influential factor trailed by feed and weight % of graphene oxide. The proposed approach predicts the outcomes of the developed model for an optimal set of parameters. It has been validated by a confirmatory test, which shows a satisfactory agreement with the actual data. The lower feed plays a vital role in surface finishing. At lower feed, the development of the defect and cracks are found less with an improved surface finish. The proposed module demonstrates the feasibility of controlling quality and productivity factors.

Titanium alloy (Ti-6Al-4V) has been extensively used in aircraft turbine-engine components, aircraft structural components, aerospace fasteners, high performance automotive parts, marine applications, medical devices and sports equipment. However, wide-spread use of this alloy has limits because of difficulty to machine it. One of the major difficulties found during machining is development of poor quality of surface in the form of higher surface roughness. The present investigation has been concentrated on studying the effects of cutting parameters of cutting speed, feed rate and depth of cut on surface roughness of the product during turning of titanium alloy. Box-Behnken experimental design was used to collect data for surface roughness. ANOVA was used to determine the significance of the cutting parameters. The model equation is also formulated to predict surface roughness. Optimal values of cutting parameters were determined through response surface methodology. A 100% desirability level in the turning process for economy was indicated by the optimized model. Also, the predicted values that were obtained through regression equation were found to be in close agreement to the experimental values.

The article presents an example of finishing treatment for aluminum alloys with the use of vibration machining, with loose abrasive media in a closed tumbler. For the analysis of selected properties of the surface layer prepared flat samples of aluminum alloy PA6/2017 in the state after recrystallization. The samples in the first stage were subjected to a treatment of deburring using ceramic media. In a second step polishing process performed with a strengthening metal media. In addition, for comparative purposes was considered. only the case of metal polishing. The prepared samples were subjected to hardness tests and a tangential tensile test. As a result of finishing with vibratory machining, it was possible to remove burrs, flash, rounding sharp edges, smoothing and lightening the surface of objects made. The basic parameters of the surface geometry were obtained using the Talysurf CCI Lite - Taylor Hobson optical profiler. As a result of the tests it can be stated that the greatest reduction of surface roughness and mass loss occurs in the first minutes of the process. Mechanical tests have shown that the most advantageous high values of tensile strength and hardness are obtained with two-stage vibration treatment, - combination of deburring and polishing. Moreover the use of metal media resulted in the strengthening of the surface by pressure deburring with metal media.

The work presented here, concentrates on experimental surface roughness analysis in the milling of hardened steel using a monolithic torus mill. Machined surface roughness with respect to milling process dynamics has been investigated. The surface roughness model including cutter displacements has been developed. Cutting forces and cutter displacements (vibrations) were measured in order to estimate their quantitative influence on Ra and Rz parameters. The cutter displacements were measured online using a scanning 3D laser vibrometer. The influence of cutting speed vc on surface roughness parameters (Ra, Rz) was also studied. The research revealed that real surface roughness parameters are significantly higher than those calculated on the basis of a kinematic-geometric basic model, and their values are strongly dependent on dynamic cutter displacements.

This paper presents a comprehensive methodology for measuring and characterizing the surface topographies on machined steel parts produced by precision machining operations. The performed case studies concern a wide spectrum of topographic features of surfaces with different geometrical structures but the same values of the arithmetic mean height Sa. The tested machining operations included hard turning operations performed with CBN tools, grinding operations with Al2O3 ceramic and CBN wheels and superfinish using ceramic stones. As a result, several characteristic surface textures with the Sa roughness parameter value of about 0.2 μm were thoroughly characterized and compared regarding their potential functional capabilities. Apart from the standard 2D and 3D roughness parameters, the fractal, motif and frequency parameters were taken in the consideration.

This study proposes a surface profile and roughness measurement system for a fibre-optic interconnect based on optical interferometry. On the principle of Fizeau interferometer, an interference fringe is formed on the fibre end-face of the fibre-optic interconnect, and the fringe pattern is analysed using the Fast Fourier transform method to reconstruct the surface profile. However, as the obtained surface profile contains some amount of tilt, a rule for estimating this tilt value is developed in this paper. The actual fibre end-face surface profile is obtained by subtracting the estimated tilt amount from the surface profile, as calculated by the Fast Fourier transform method, and the corresponding surface roughness can be determined. The proposed system is characterized by non-contact measurement, and the sample is not coated with a reflector during measurement. According to the experimental results, the difference between the roughness measurement result of an Atomic Force Microscope (AFM) and the measurement result of this system is less than 3 nm.

Aluminum alloys are widely used today in plastic injection molds in the automotive and aerospace industries due to their high strength and weight ratio, good corrosion and fatigue resistance as well as high feed rates. The 5754 aluminum alloy has high corrosion resistance and a structure suitable for cold forming. In this study, an AA 5754-H111 tempered aluminum alloy with the dimensions of 80×80×30 mm was used, and some of the materials were cryogenically heat treated. For the milling operations, ϕ12 mm diameter 76 mm height uncoated as well as TiCN and TiAlN coated end mills were used. Different levels of cutting depth (1.25, 2.0, 2.5 mm), cutting speed (50, 80, 100 m/ min), feed rate (265, 425, 530 m/ min) and machining pattern (concentric, back and forth and inward helical) were used. The number of experiments was reduced from 486 to 54 using the Taguchi L54 orthogonal array. The values obtained at the end of the experiments were evaluated using the signal-to-noise ratio, ANOVA, three-dimensional graphs and the regression method. Based on the result of the verification experiments, the processing accuracy for surface roughness was improved from 3.20 μm to 0.90 μm, with performance increase of 71.88%.

In this paper, the basic cutting characteristics such as cutting forces, cutting power and its distribution, specific cutting energies were determined taking into account variable tool corner radius ranging from 400 to 1200 μm and constant cutting parameters typical for hard turning of a hardened 41Cr4 alloy steel of 55 ± 1 HRC hardness. Finish turning operations were performed using chamfered CBN tools. Moreover, selected roughness profiles produced for different tool corner radius were compared and appropriate surface roughness parameters were measured. The measured values of Ra and Rz roughness parameters are compared with their theoretical values and relevant material distribution curves and bearing parameters are presented.

In the paper, the author analyses a model of a ring pack motion on an oil film. The local thickness of the oil film can be compared to the height of the combined surface roughness of a cylinder liner and piston rings. Equations describing the mixed lubrication problem based on the empirical mathematical model formulated in works by Patir, Cheng [6, 7] and Greenwood, Tripp [3] have been combined [13] and used in this paper. A model of a gas flow through the labyrinth seal of piston rings has been developed [14,16]. In addition, models of ring twist effects and axial ring motion in piston grooves have been applied [15,16].

In contrast to the previous papers of the author, an experimental verification of the main parts of developed mathematical model and software has been presented. A relatively good compatibility between the experimental measurements and calculated results has been achieved.

Titania dioxide (TiO₂) layers were synthesized via the acid-catalysed sol-gel route using titania (IV) ethoxide, and then annealed at temperatures varying in the range of 150–700 °C. The research concerned the effect of annealing temperature on the structure of TiO₂ layers, their surface morphology, and their optical properties. Further, X-ray diffractometry, and Raman spectroscopy were used to determine the structure of TiO₂ layers. Scanning electron and atomic force microscopy were used to study the surface morphology of TiO₂ layers. Transmittance, reflectance, absorption edge, and optical homogeneity were investigated by UV-VIS spectrophotometry, while the refractive index and thicknesses of TiO₂ layers were measured using a monochromatic ellipsometer. Chromatic dispersion characteristics of the complex refractive index were determined using spectroscopic ellipsometry. Structural studies have shown that the TiO₂ layers annealed at temperatures up to 300 °C are amorphous, while those annealed at temperatures exceeding 300 °C are polycrystalline containing only anatase nanocrystals with sizes increasing from 6 to 20 nm with the increase of the annealing temperature. Investigations on the surface morphology of TiO₂ layers have shown that the surface roughness increases with the increase in annealing temperature. Spectrophotometric investigations have shown that TiO₂ layers are homogeneous and the width of the indirect optical band gap varies with annealing temperature from 3.53 eV to 3.73 eV.

The article presents the results of research on the finishing of M63 Z4 brass by vibratory machining. Brass alloy was used for the research due to the common use of ammunition elements, cartridge case and good cold forming properties on the construction. Until now, the authors have not met with the results of research to determine the impact of abrasive pastes in container processing. It was found that the additive for container abrasive treatment of abrasive paste causes larger mass losses and faster surface smoothing effects. The treatment was carried out in two stages: in the first stage, the workpieces were deburred and then polished. Considerations were given to the impact of mass of workpieces, machining time and its type on mass loss and changes in the geometric structure of the surface. The surface roughness of machining samples was measured with the Talysurf CCI Lite optical profiler. The suggestions for future research may be to carry out tests using abrasive pastes with a larger granulation of abrasive grains, and to carry out tests for longer processing times and to determine the time after which the parameters of SGP change is unnoticeable.

This article proposes these of vibratory machining to Ti-6Al-4V titanium alloy as finishing treatment. Titanium alloy was used in the aerospace industry, military, metallurgical, automotive and medical processes, extreme sports and other. The three-level three-factor Box-Behnken experiment examined the influence of machining time of vibratory machining, the type of mass finishing media used and the initial state of the surface layer on the mass loss, geometric structure of the surface, micro hardness and the optimal process parameters were determined. Considerations were given the surfaces after milling, after cutting with a band saw and after the sanding process. The experiment used three types of mass finishing media: polyester, porcelain and metal. Duration of vibratory machining treatment was assumed to be 20, 40, 60 minutes. The form profiles before and after vibratory machining were determined with the Talysurf CCI Lite - Taylor Hobson optical profiler. Future tests should concern research to carry out tests using abrasive pastes with a larger granulation of abrasive grains, to carry out tests for longer processing times and to determine the time after which the parameters of geometrical structure of the surface change is unnoticeable.