Influence of high-speed milling parameter on 3D surface topography and fatigue behavior of TB6 titanium alloy

High-speed milling of titanium alloys is widely used in aviation and aerospace industries for its high efficiency and good quality.In order to optimize the machining parameters in high-speed milling TB6 titanium alloy,experiments of high-speed milling and fatigue were conducted to investigate the effect of parameters on 3D surface topography and fatigue life.Based on the fatigue fracture,the effect mechanism of surface topography on the fatigue crack initiation was proposed.The experiment results show that when the milling speed ranged from 100 m/min to 140 m/min,and the feed per tooth ranged from 0.02 mm/z to 0.06 mm/z,the obtained surface roughness were within the limit（0.8 μm）.Fatigue life decreased sharply with the increase of surface equivalent stress concentration factor.The average error of fatigue life between the established model and the experimental results was 6.25%.The fatigue cracks nucleated at the intersection edge of machined surface.

Running-in Test and Fractal Methodology for Worn Surface Topography Characterization

Studying and understanding of the surface topography variation are the basis for analyzing tribological problems,and characterization of worn surface is necessary.Fractal geometry offers a more accurate description for surface roughness that topographic surfaces are statistically self-similar and can be quantitatively evaluated by fractal parameters.The change regularity of worn surface topography is one of the most important aspects of running-in study.However,the existing research normally adopts only one friction matching pair to explore the surface topography change,which interrupts the running-in wear process and makes the experimental result lack authenticity and objectivity.In this paper,to investigate the change regularity of surface topography during the real running-in process,a series of running-in tests by changing friction pairs under the same operating conditions are conducted on UMT-II Universal Multifunction Tester.The surface profile data are acquired by MiaoXAM2.5X-50X Ultrahigh Precision Surface 3D Profiler and analyzed using fractal dimension D,scale coefficient C and characteristic roughness Ra ＊based on root mean square（RMS） method.The characterization effects of the three parameters are discussed and compared.The results obtained show that there exists remarkable fractal feature of surface topography during running-in process,both D and Ra ＊increase gradually,while C decreases slowly as the wear-in process goes on,and all parameters tend to be stable when the wear process steps into the normal wear process.Ra ＊illustrates higher sensitivity for rough surface characterization compared with the other two parameters.In addition,the running-in test carried with a set of identical surface properties is more scientific and reasonable than the traditional one.The proposed research further indicates that the fractal method can quantitatively measure the rough surface,which also provides an evidence for running-in process identification and tribology design.

Fatigue life prediction of workpiece with 3D rough surface topography based on surface reconstruction technology

The fatigue performance of a workpiece depends on its surface quality.In traditional fatigue life prediction,the effect of surface quality is commonly accounted for by using empirical correction factors,which is imprecise when safety is of great concern.For surface quality,the surface topography is an important parameter,which introduces stress concentration that reduces the fatigue life.It is not feasible to test the stress concentration of different surface topographies.On the one hand,it is time-consuming and high-cost,and on the other hand,it cannot reflect the general statistical characteristics.With the help of surface reconstruction technology and interpolation method,a more efficient and economic approach is proposed,where FE simulation of workpiece with the reconstructed surface topography is used as a foundation for fatigue life prediction.The relationship between surface roughness(Sa)and fatigue life of the workpiece is studied with the proposed approach.

Surface Topography and Roughness of High-speed Milled AlMn1Cu

The aluminum alloy AlMn1Cu has been broadly applied for functional parts production because of its good properties. But few researches about the machining mechanism and the surface roughness were reported. The high-speed milling experiments are carried out in order to improve the machining quality and reveal the machining mechanism. The typical topography features of machined surface are observed by scan electron microscope（SEM）. The results show that the milled surface topography is mainly characterized by the plastic shearing deformation surface and material piling zone. The material flows plastically along the end cutting edge of the flat-end milling tool and meanwhile is extruded by the end cutting edge, resulting in that materials partly adhere to the machined surface and form the material piling zone. As the depth of cut and the feed per tooth increase, the plastic flow of materials is strengthened and the machined surface becomes rougher. However, as the cutting speed increases, the plastic flow of materials is weakened and the milled surface becomes smoother. The cutting parameters （e.g. cutting speed, feed per tooth and depth of cut） influencing the surface roughness are analyzed. It can be concluded that the roughness of the machined surface formed by the end cutting edge is less than that by the cylindrical cutting edge when a cylindrical flat-end mill tool is used for milling. The proposed research provides the typical topography features of machined surface of the anti-rust aluminum alloy AlMn1Cu in high speed milling.

Bending strength and fracture surface topography of natural fiber-reinforced shell for investment casting process

In order to improve the properties of silica sol shell for investment casting process, various contents of cattail fibers were added into the slurry to prepare a fiber-reinforced shell in the present study. The bending strength of fiber-reinforced shell was investigated and the fracture surfaces of shell specimens were observed using SEM. It is found that the bending strength increases with the increase of fiber content, and the bending strength of a green shell with 1.0 wt.% fiber addition increases by 44% compared to the fiber-free shell. The failure of specimens of the fiber-reinforced green shell results from fiber rupture and debonding between the interface of fibers and adhesive under the bending load. The micro-crack propagation in the matrix is inhibited by the micro-holes for ablation of f ibers in specimens of the f iber-reinforced shell during the stage of being fired. As a result, the bending strength of specimens of the fired shell had no significant drop. Particularly, the bending strength of specimens of the fired shell reinforced with 0.6wt.% fiber reached the maximum value of 4.6 MPa.

Effect of Surface Topography on Stress Concentration Factor

Neuber rule and Arola-Ramulu model are widely used to predict the stress concentration factor of rough specimens. However, the height parameters and effective valley radius used in these two models depend strongly on the resolution of the roughness-measuring instruments and are easily introduce measuring errors. Besides, it is difficult to find a suitable parameter to characterize surface topography to quantitatively describe its effect on stress concentration factor. In order to overcome these disadvantages, profile moments are carried out to characterize surface topography, surface topography is simulated by superposing series of cosine components, the stress concentration factors of different micro cosine-shaped surface topographies are investigated by finite element analysis. In terms of micro cosine-shaped surface topography, an equation using the second profile moment to estimate the stress concentration factor is proposed, predictions for the stress concentration factor using the proposed expression are within 10% error compared with the results of finite element analysis, which are more accurate than other models. Moreover, the proposed equation is applied to the real surface topography machined by turning. Predictions for the stress concentration factor using the proposed expression are within 10% of the maximum stress concentration factors and about 5% of the effective stress concentration factors estimated from the finite element analysis for three levels of turning surface topographies under different simulated scales. The proposed model is feasible in predicting the stress concentration factors of real machined surface topographies.

3D Evaluation Method of Cutting Surface Topography of Carbon / Phenolic (C/Ph) Composite

3D evaluation method of cutting surface topography for C/Ph composites was established.The cutting surface was measured by Talyscan 150,using 3D non-contact measurement.Through the results of 2D and 3D roughness evaluating for C/Ph composite and Duralumin,the 2D evaluation method of the cutting surface topography of C/Ph composite loses a lot of information,the characteristics of the surface topography of C/Ph composite can be comprehensively and authentically evaluated only by 3D evaluation method.Furthermore,3D amplitude and spatial parameters were adopted to evaluate the surface.The results show that： the topography of the C/Ph composite is anisotropic,there are more valleys in the machined surface of C/Ph than that of duralumin,and there are not obvious feeding textures for C/Ph,which indicates the machining mechanism is different from the metal.In conclusion,the topography of the C/Ph composite cutting surface is anisotropic;the cutting surface of C/Ph composite needs 3D evaluation method.

Effect of electrochemical polishing time on surface topography of mild steel

The variation in altitude density function （ADF） of the surface topography of mild steel during electrochemical polishing （ECP） was investigated, and the mechanism of the variation of surface roughness with polishing time was analyzed. The results show that the variation trend of ADF with polishing time is flat-steep-flat; the variation of surface roughness results in the different distri- butions of surface current density, and there is a fine surface smoothness in the special period of ECP from 4 to 8 s.

A 3D evaluation method of cutting surface topography of carbon/carbon(C/C) composite

This paper aims to establish a 3D evaluation method for cutting surface topography of C/C composites. The cutting surface is measured by Talyscan 150, using 3D non-contact measurement. By evaluating 2D and 3D roughness of C/C composite and Duralumin, the 2D evaluation method of the cutting surface topography of C/C composite loses a lot of information, and the characteristics of the surface topography of C/C composite can be comprehensively and authentically evaluated only by the 3D evaluation method. Furthermore, 3D amplitude and spatial parameters are adopted to evaluate the surface and the results show that： the topography of the C/C composite is anisotropy and there are no obvious feeding textures but abrupt peaks and valleys on surface of the C/C composite, which indicates that the machining mecha- nism is different from that of the metal. In conclusion, The C/C composite surface is evaluated using a 3D evaluation method, the roughness error is small, and the unique topography characteristics earl be au- thentically evaluated.

Surface Topography of Fine-grained ZrO_2 Ceramic by Two-dimensional Ultrasonic Vibration Grinding

The surface quality of fine-grained ZrO2 engineering ceramic were researched using 270# diamond wheel both with and without work-piece two-dimension ultrasonic vibration grinding（WTDUVG）. By AFM images, the surface topography and the micro structure of the two-dimensional ultrasonic vibration grinding ceramics were especially analyzed. The experimental results indicate that the surface roughness is related to grinding vibration mode and the material removal mechanism. Surface quality of WTDUVG is superior to that of conventional grinding, and it is easy for two-dimensional ultrasonic vibration grinding that material removal mechanism is ductile mode grinding.

3D surface topography formation in ultra-precision turning

The generation process of 3D surface topography in ultra-precision turning is analyzed, as the result of superimposing between actual roughness surface,waviness surface and geometrical form texture surface. From the viewpoints of machine technical system and manufacturing process,factors influencing on roughness surface, waviness surface and geometrical form texture surface in ultra-precision turning are discussed further.The 3D topography of ideal roughness surface and actual surface affected by cutting vibration are simulated respectively.

The Characteristics of the Surface Topography of Excimer Laser Processed Al_2O_3 Ceramic

Surface of Al 2O 3 ceramic was processed by an excimer laser and the characteristics of topography were examined based on the application of the microelectromechanical system(MEMS). It is indicated that the statistic parameters of surface topography processed by the excimer laser have an obvious regularity. The arithmetic-mean value R a and the root-mean square value R q change with the changing of processing parameters in the same step and trend, and there is a quantitative relation between them.A simplified model is proposed for the excimer laser processing surface profile, whose results of the analysis and calculation agree basically with the experimental data. Furthermore,the surfaces processed by excimer laser are greatly flat. Skewness root-mean-square value Z· q changed little with the change of the technological parameters. The above characteristics depend on the processing principle of excimer laser, quite different from the cutting processing.

A novel wide-range precision instrument for measuring three-dimensional surface topography

We developed a measuring instrument that had wide range, high precision, small measuring touch force. The instrument for three-dimensional (3D) surface topography measurement was composed of a high precision displacement sensor based on the Michelson interference principle, a 3D platform based on vertical scanning, a measuring and control circuit, and an industrial control computer. It was a closed loop control system, which changed the traditional moving stylus scanning style into a moving platform scanning style. When the workpiece was measured, the lever of the displacement sensor returned to the balanced position in every sample interval according to the zero offset of the displacement sensor. The non-linear error caused by the rotation of the lever was, therefore, very small even if the measuring range was wide. The instrument can measure the roughness and the profile size of a curved surface.

Effect of Pb content on the surface topography and corrosion resistance of hot dip Zn-Al-Mg coatings

In this study,the effect of Pb content on the surface morphology and salt spray corrosion resistance of hot dip Zn-AI-Mg coatings was investigated. The results showed that the coating surface easily formed small grains of zinc spangle structures and that the salt spray con＇osion resistance of the coating decreased when Pb content was greater than 0.01%. The microstructure and energy dispersive spectrum analysis of surface and cross-sectional areas was performed by scanning electron microscopy. Pb content present in the coating was analyzed by glow discharge spectrum. The results showed that the distribution of Pb in the coating was not uniform. The Pb content was segregated on the surface and at the cross-section of the Zn-A1-MgZn2 ternary eutectic structure,especially,on the surface of the Zn-A1-MgZn2 ternary eutectic structure.

Generating synthetic as-built additive manufacturing surface topography using progressive growing generative adversarial networks

Numerically generating synthetic surface topography that closely resembles the features and characteristics of experimental surface topography measurements reduces the need to perform these intricate and costly measurements.However,existing algorithms to numerically generated surface topography are not well-suited to create the specific characteristics and geometric features of as-built surfaces that result from laser powder bed fusion(LPBF),such as partially melted metal particles,porosity,laser scan lines,and balling.Thus,we present a method to generate synthetic as-built LPBF surface topography maps using a progressively growing generative adversarial network.We qualitatively and quantitatively demonstrate good agreement between synthetic and experimental as-built LPBF surface topography maps using areal and deterministic surface topography parameters,radially averaged power spectral density,and material ratio curves.The ability to accurately generate synthetic as-built LPBF surface topography maps reduces the experimental burden of performing a large number of surface topography measurements.Furthermore,it facilitates combining experimental measurements with synthetic surface topography maps to create large data-sets that facilitate,e.g.relating as-built surface topography to LPBF process parameters,or implementing digital surface twins to monitor complex end-use LPBF parts,amongst other applications.

High-precision simulation and experimental verification of residual stress and surface topography of cylindrical surface shot peening

Shot peening is commonly employed for surface deformation strengthening of cylindrical surface part.Therefore,it is critical to understand the effects of shot peening on residual stress and surface topography.Compared to flat surface,cylindrical surface shot peening has two significant features:(i)the curvature of the cylindrical surface and the scattering of the shot stream cause dis-tributed impact velocities;(i)the rotation of the part results in a periodic variation of the impact velocity component.Therefore,it is a challenge to quickly and accurately predict the shot peening residual stress and surface topography of cylindrical surface.This paper developed a high-precision model which considers the more realistic shot peening process.Firstly,a kinematic analysis model was developed to simulate the relative movement of numerous shots and cylindrical surface.Then,the spatial distribution and time-varying impact information was calculated.Subsequently,the impact information was used for finite element modeling to predict residual stress and surface topography.The proposed kinematic analysis method was validated by comparison with the dis-crete element method.Meanwhile,9310 high strength steel rollers shot peening test verified the effectiveness of the model in predicting the residual stress and surface topography.In addition,the effects of air pressure and attack angle on the residual stress and surface topography were investigated.This work could provide a functional package for efficient prediction of the surface integrity and guide industrial application in cylindrical surface shot peening.

Unveiling three-dimensional sea surface signatures caused by internal solitary waves:insights from the surface water ocean topography mission

Internal solitary waves(ISW),characterized by large amplitude and long propagation distance,are widespread in global oceans.While remote sensing images have played an essential role in studying ISWs,they mainly exploit two-dimensional image information.However,with the launch of the surface water ocean topography(SWOT)satellite on December 16,2022,a unique opportunity has emerged to capture wide-swath three-dimensional ISW-induced sea surface information.In this study,we examine ISWs in the Andaman Sea using data from the Ka-band Radar Interferometer(KaRIN),a crucial sensor onboard SWOT.KaRIN not only provides backscattering satellite images but also employs synthetic aperture interferometry techniques to retrieve wide-swath two-dimensional sea surface height measurements.Our observations in the Andaman Sea revealed the presence of ISWs characterized by dark-bright strips and surface elevation solitons.The surface soliton has an amplitude of 0.32 m,resulting in an estimation of ISW amplitude of approximately 60 m.In contrast to traditional two-dimensional satellite images or nadir-looking altimetry data,the SWOT mission’s capability to capture threedimensional sea surface information represents a significant advancement.This breakthrough holds substantial promise for ISW studies,particularly in the context of ISW amplitude inversion.

Experimental and modeling study of surface topography generation considering tool-workpiece vibration in high-precision turning

High-precision turning(HPT)is a main processing method for manufacturing rotary high-precision components,especially for metallic parts.However,the generated vibration between tool tip and workpiece during turning may seriously deteriorate the surface integrity.Therefore,exploring the effect of vibration on turning surface morphology and quality of copper parts using 3D surface topography regeneration model is crucial for predicting HPT performance.This developed model can update the machined surface topology in real time.In this study,the effects of tool arc radius,feed rate,radial vibration,axial vibration and tangential vibration on the surface topography and surface roughness were explored.The results show that the effect of radial vibration on surface topography is greater than that of axial vibration and tangential vibration.The radial vibration frequency is also critical.When vibration frequency changes,the surface topography profile presents three different types:the standard sinusoidal curve,the sinusoidal curve whose lowfrequency signal envelopes high-frequency signal,and the oscillation curve whose low-frequency signal superimposes high-frequency signal.In addition,HPT experiment was carried out to validate the developed model.The surface roughness obtained in the experiment was Ra=53 nm,while the roughness obtained by the simulation was Ra=46 nm,achieving a prediction accuracy of 86.7%.Received 4 September 2022;revised 3 October 2022;accepted 17 October 2022.

Study of the ability of SWOT to detect sea surface height changes caused by internal solitary waves

Surface Water and Ocean Topography(SWOT)is a next-generation radar altimeter that offers high resolution,wide swath,imaging capabilities.It has provided free public data worldwide since December 2023.This paper aims to preliminarily analyze the detection capabilities of the Ka-band radar interferometer(KaRIn)and Nadir altimeter(NALT),which are carried out by SWOT for internal solitary waves(ISWs),and to gather other remote sensing images to validate SWOT observations.KaRIn effectively detects ISW surface features and generates surface height variation maps reflecting the modulations induced by ISWs.However,its swath width does not completely cover the entire wave packet,and the resolution of L2/L3 level products(about 2 km)cannot be used to identify ISWs with smaller wavelengths.Additionally,significant wave height(SWH)images exhibit blocky structures that are not suitable for ISW studies;sea surface height anomaly(SSHA)images display systematic leftright banding.We optimize this imbalance using detrending methods;however,more precise treatment should commence with L1-level data.Quantitative analysis based on L3-level SSHA data indicates that the average SSHA variation induced by ISWs ranges from 10 cm to 20 cm.NALTs disturbed by ISWs record unusually elevated SWH and SSHA values,rendering the data unsuitable for analysis and necessitating targeted corrections in future retracking algorithms.For the normalized radar cross section,Ku-band and four-parameter maximum likelihood estimation retracking demonstrated greater sensitivity to minor changes in the sea surface,making them more suitable for ISW detection.In conclusion,SWOT demonstrates outstanding capabilities in ISW detection,significantly advancing research on the modulation of the sea surface by ISWs and remote sensing imaging mechanisms.

Nature-inspired surface topography: design and function

Learning from nature has traditionally and continuously provided important insights to drive a paradigm shift in technology.In particular,recent studies show that many biological organisms exhibit spectacular surface topography such as shape,size,spatial organization,periodicity,interconnectivity,and hierarchy to endow them with the capability to adapt dynamically and responsively to a wide range of environments.More excitingly,in a broader perspective,these normally neglected topological features have the potential to fundamentally change the way of how engineering surface works,such as how fluid flows,how heat is transported,and how energy is generated,saved,and converted,to name a few.Thus,the design of nature-inspired surface topography for unique functions will spur new thinking and provide paradigm shift in the development of the new engineering surfaces.In this review,we first present a brief introduction to some insights extracted from nature.Then,we highlight recent progress in designing new surface topographies and demonstrate their applications in emerging areas including thermal-fluid transport,anti-icing,water harvesting,power generation,adhesive control,and soft robotics.Finally,we offer our perspectives on this emerging field,with the aim to stimulate new thinking on the development of next-generation of new materials and devices,and dramatically extend the boundaries of traditional engineering.