Theoretical Modeling and Surface Roughness Prediction of Microtextured Surfaces in Ultrasonic Vibration-Assisted Milling

Textured surfaces with certain micro/nano structures have been proven to possess some advanced functions,such as reducing friction,improving wear and increasing wettability.Accurate prediction of micro/nano surface textures is of great significance for the design,fabrication and application of functional textured surfaces.In this paper,based on the kinematic analysis of cutter teeth,the discretization of ultrasonic machining process,transformation method of coordinate systems and the cubic spline data interpolation,an integrated theoretical model was established to characterize the distribution and geometric features of micro textures on the surfaces machined by different types of ultrasonic vibration-assisted milling(UVAM).Based on the theoretical model,the effect of key process parameters(vibration directions,vibration dimensions,cutting parameters and vibration parameters)on tool trajectories and microtextured surface morphology in UVAM is investigated.Besides,the effect of phase difference on the elliptical shape in 2D/3D ultrasonic elliptical vibration-assisted milling(UEVAM)was analyzed.Compared to conventional numerical models,the method of the cubic spline data interpolation is applied to the simulation of microtextured surface morphology in UVAM,which is more suitable for characterizing the morphological features of microtextured surfaces than traditional methods due to the presence of numerous micro textures.The prediction of surface roughness indicates that the magnitude of ultrasonic amplitude in z-direction should be strictly limited in 1D rotary UVAM,2D and 3D UEVAM due to the unfavorable effect of axial ultrasonic vibration on the surface quality.This study can provide theoretical guidance for the design and fabrication of microtextured surfaces in UVAM.

Influence of Surface Ice Roughness on the Aerodynamic Performance of Wind Turbines

The focus of this research was on the equivalent particle roughness height correction required to account for the presence of ice when determining the performances of wind turbines.In particular,two icing processes(frost ice and clear ice)were examined by combining the FENSAP-ICE and FLUENT analysis tools.The ice type on the blade surfaces was predicted by using a multi-time step method.Accordingly,the influence of variations in icing shape and ice surface roughness on the aerodynamic performance of blades during frost ice formation or clear ice formation was investigated.The results indicate that differences in blade surface roughness and heat flux lead to disparities in both ice formation rate and shape between frost ice and clear ice.Clear ice has a greater impact on aerodynamics compared to frost ice,while frost ice is significantly influenced by the roughness of its icy surface.

Mechanical properties and fracture surface roughness of thermally damaged granite under dynamic splitting

In order to understand the mechanical properties and the fracture surface roughness characteristics of thermally damaged granite under dynamic splitting,dynamic Brazilian splitting tests were conducted on granite samples after thermal treatment at 25,200,400,and 600℃.Results show that the dynamic peak splitting strength of thermally damaged granite samples increases with increasing strain rate,showing obvious strain‐rate sensitivity.With increasing temperature,thermally induced cracks in granite transform from intergranular cracks to intragranular cracks,and to a transgranular crack network.Thermally induced damages reduce the dynamic peak splitting strength and the maximum absorbed energy while increasing the peak radial strain.The fracture mode of the thermally damaged granite under dynamic loads is mode Ⅱ splitting failure.By using the axial roughness index Z2 a,the distribution ranges of the wedge‐shaped failure zones and the tensile failure zones in the fracture surfaces under dynamic Brazilian splitting can be effectively identified.The radial roughness index Z_(2)^(r)is sensitive to the strain rate and temperature.It shows a linear correlation with the peak splitting strength and the maximum absorbed energy and a linear negative correlation with the peak radial strain.Z_(2)^(r)can be used to quantitatively estimate the dynamic parameters based on the models proposed.

Effects of surface roughness of substrate on properties of Ti/TiN/Zr/ZrN multilayer coatings

Ti/TiN/Zr/ZrN multilayer coatings were deposited on Cr_17Ni_2 steel substrates with different surface roughnesses by vacuum cathodic arc deposition method. Microstructure, micro-hardness, adhesion strength and cross-sectional morphology of the obtained multilayer coatings were investigated. The results show that the Vickers hardness of Ti/TiN/Zr/ZrN multilayer coating, with a film thickness of 11.37 μm, is 29.36 GPa. The erosion and salt spray resistance performance of Cr_17Ni_2 steel substrates can be evidently improved by Ti/TiN/Zr/ZrN multilayer coating. The surface roughness of Cr_17Ni_2 steel substrates plays an important role in determining the mechanical and erosion performances of Ti/TiN/Zr/ZrN multilayer coatings. Overall, a low value of the surface roughness of substrates corresponds to an improved performance of erosion and salt spray resistance of multilayer coatings. The optimized performance of Ti/TiN/Zr/ZrN multilayer coatings can be achieved provided that the surface roughness of Cr_17Ni_2 steel substrates is lower than 0.4μm.

Effect of surface roughness on plasticity of Zr_(52.5)Cu_(17.9)Ni_(14.6)Al_(10)Ti_5 bulk metallic glass

Zr52.5Cu17.9Ni14.6Al10Ti5 bulk metallic glass （BMG） rods were abraded to different surface roughnesses using different types of waterproof abrasive papers and sometimes polishing pastes, and the compressive deformation behavior was examined. The results show that the yield strength of the BMG is hardly affected while the compressive plasticity increases from 2.3% to 4.5% with decreasing the surface roughness. Observation of the fractured samples under a scanning electron microscope indicates that the rise in plasticity is accompanied with an increase in shear band density. The results suggest that it is necessary to reduce the surface roughness of BMGs for achieving a large plasticity.

SURFACE ROUGHNESS EVOLUTION AND FORMABILITY OF INTERSTITIAL FREE SHEET STEEL TO GRAIN SIZE AND SHEET THICKNESS

Experimental study has been conducted for an interstitial free(IF) sheet steel on its surface roughness evolution and formability with respect to grain size and sheet thickness effect. The surface roughness of IF sheet steel is proportional to effective strain, grain size and inversely proportional to sheet thickness; the larger grain reduces the formability by accelerating the surface roughening rate and enhance formability by raising the workhardening rate, while the latter effect plays the dominate role. The grain size effect on surface roughening and formability is more obvious when the sheets are thinner.

SIMULATION ANALYSIS OF INFLUENCE OF ROAD SURFACE ROUGHNESS ON TYRE DYNAMIC PERFORMANCE IN AUTOMOTIVE BRAKING

Using a nonlinear time varying tyre model, this paper simulatively analyzes the influence of road surface roughness amplitude and road spatial frequency on automobile ground adhesion ability. The result shows that with the increase of road surface roughness, the tyre adhesion ability declines, and the automotive braking distance increases. Moreover, the reliability of the nonlinear time varying tyre model in reflecting the influence of the road surface roughness is validated. It is testified that this model is an effective dynamic one in the simulation of automotive braking performance on uneven road.

Sea Surface Roughness Derivation from Wind Speed Estimated by Satellite Altimeter

For open sea conditions the sea surface roughness is described as a function of surface stress and wind speed over sea surface by Charnock relation. The sea surface roughnessn in the North-west Pacific Ocean is derived successfully using wind speed data estimated by the TOPEX satellite altimeter. From the results we find that： （1） the mean sea surface roughness in winter is greater than in summer; （2） compared with other sea areas, the sea surface roughness in the sea area east of Japan （ N30°- 40°, E135°- 150°） is larger than in other sea areas; （3） sea surface roughness in the South China Sea changes more greatly than that in the Bohai Sea, Yellow Sea and East China Sea.

The Simulation of Grinding Wheels and Ground Surface Roughness Based on Virtual Reality Technology

The paper describes the feasibility and method of the application of virtual reality technology to grinding process, and introduces the modeling method of object entity in the environment of virtual reality. The simulation process of grinding wheels and ground surface roughness is discussed, and the computation program system of numerical simulation is compiled with Visual C++ programming language. At the same time, the three-dimensional simulation models of grinding wheels and ground surface roughness are made with OpenGL tool. The choice of grinding wheels, the forecast of ground surface quality and some simulation results can be realized by interactively inputting grinding parameters. The paper applies virtual reality technology to grinding process,makes the model of virtual grinding wheel and simulates the grinding process. The roughness of ground surface is showed in three-dimensional images, and therefore the grinding technology is studied. Computer simulation can not only be used as a shortcut to analyze and research the grinding process, but also increase the research scope and content. The virtual reality technology used in the paper is an advanced visualized simulation with interaction. The surface roughness Ra on simulated ground workpiece can be calculated by the arithmetic average of contour warp absolute value in sampling length of simulated ground workpiece. The parameters of virtual wheel and simulated grinding process can be changed by interaction input, so the simulated results in the desired grinding condition are gained. The effect of each parameter to ground surface can be analyzed by comparing the grinding results in different condition.

Soil surface roughness change and its effect on runoff and erosion on the Loess Plateau of China

As an important parameter in the soil erosion model, soil surface roughness（SSR） is used to quantitatively describe the micro-relief on agricultural land. SSR has been extensively studied both experimentally and theoretically; however, no studies have focused on understanding SSR on the Loess Plateau of China. This study investigated changes in SSR for three different tillage practices on the Loess Plateau of China and the effects of SSR on runoff and erosion yield during simulated rainfall. The tillage practices used were zero tillage（ZT）, shallow hoeing（SH） and contour ploughing（CP）. Two rainfall intensities were applied, and three stages of water erosion processes（splash erosion（I）, sheet erosion（II） and rill erosion（III）） were analyzed for each rainfall intensity. The chain method was used to measure changes in SSR both initially and after each stage of rainfall. A splash board was used to measure the splash erosion at stage I. Runoff and sediment data were collected continuously at 2-min intervals during rainfall erosion stages II and III. We found that SSR of the tilled surfaces ranged from 1.0% to 21.9% under the three tillage practices, and the order of the initial SSR for the three treatments was ZT〈SH〈CP. For the ZT treatment, SSR increased slightly from stage I to III, whereas for the SH and CP treatments, SSR decreased by 44.5% and 61.5% after the three water erosion stages, respectively, and the greatest reduction in SSR occurred in stage I. Regression analysis showed that the changes in SSR with increasing cumulative rainfall could be described by a power function（R2〉0.49） for the ZT, SH and CP treatments. The runoff initiation time was longer in the SH and CP treatments than in the ZT treatment. There were no significant differences in the total runoff yields among the ZT, SH and CP treatments. Sediment loss was significantly smaller（P〈0.05） in the SH and CP treatments than in the ZT treatment.

Surface Roughness Around a 325-m Meteorological Tower and Its Effect on Urban Turbulence

Based on slow- and fast-response measurements under neutral stratification conditions from a 325-m meteorological tower located in a built-up area of north-central Beijing as well as a descriptive survey of surface roughness elements (i.e., buildings and trees) around the tower site, urban roughness lengths, zo, with zero-plane displacement height are estimated using logarithmic wind profile and morphometric methods in eight 45° directional sectors. When comparing their results with each other, the slow-response method tends to give smaller zo values. At a given location, considerable directional variations in values are observed. The effect of surface roughness on urban turbulence characteristics in terms of non-dimensional standard deviations of three-component velocity, σi/u*1 (where i = u, v, w and u*1 is local friction velocity), is investigated.

The Characteristics and Parameterization of Aerodynamic Roughness Length over Heterogeneous Surfaces

Aerodynamic roughness length （Z0m） is a key factor in surface flux estimations with remote sensing algorithms and/or land surface models. This paper calculates ZOrn over several land surfaces, with 3 years of experimental data from Xiaotangshan. The results show that Z0m is direction-dependent, mainly due to the heterogeneity of the size and spatial distribution of the roughness elements inside the source area along different wind directions. Furthermore, a heuristic parameterization of the aerodynamic roughness length for heterogeneous surfaces is proposed. Individual Z0m over each surface component （patch） is calculated firstly with the characteristic parameters of the roughness elements （vegetation height, leaf area index, etc.）, then Z0m over the whole experimental field is aggregated, using the footprint weighting method.

SURFACE ROUGHNESS PREDICTION MODEL FOR ULTRAPRECISION TURNING ALUMINIUM ALLOY WITH A SINGLE CRYSTAL DIAMOND TOOL

A surface roughness model utilizing regression analysis method is developedfor predicting roughness of ultra-precision machined surface with a single crystal diamond tool. Theeffects of the main variables, such as cutting speed, feed, and depth of cut on surface roughnessare also analyzed in diamond turning aluminum alloy. In order to predict the optimum cuttingconditions during process planning. A lot of experimental results show that the model can predictthe surface roughness effectively under a certain cutting conditions.

On Sea Surface Roughness Parameterization and Its Effect on Tropical Cyclone Structure and Intensity

A new parameterization scheme of sea surface momentum roughness length for all wind regimes, including high winds, under tropical cyclone （TC） conditions is constructed based on measurements from Global Positioning System （GPS） dropsonde. It reproduces the observed regime transition, namely, an increase of the drag coefficient with an increase in wind speed up to 40 m s-1 , followed by a decrease with a further increase in wind speed. The effect of this parameterization on the structure and intensity of TCs is evaluated using a newly developed numerical model, TCM4. The results show that the final intensity is increased by 10.5% （8.9%） in the maximum surface wind speed and by 8.1 hPa （5.9 hPa） in the minimum sea surface pressure drop with （without） dissipative heating. This intensity increase is found to be due mainly to the reduced frictional dissipation in the surface layer and little to do with either the surface enthalpy flux or latent heat release in the eyewall convection. The effect of the new parameterization on the storm structure is found to be insignificant and occurs only in the inner core region with the increase in tangential winds in the eyewall and the increase in temperature anomalies in the eye. This is because the difference in drag coefficient appears only in a small area under the eyewall. Implications of the results are briefly discussed.

Wave-Dependence of Friction Velocity, Roughness Length, and Drag Coefficient over Coastal and Open Water Surfaces by Using Three Databases

The parameterization of friction velocity, roughness length, and the drag coefficient over coastal zones and open water surfaces enables us to better understand the physical processes of air-water interaction. In context of measurements from the Humidity Exchange over the Sea Main Experiment （HEXMAX）, we recently proposed wave-parameter dependent approaches to sea surface friction velocity and the aerodynamic roughness by using the dimensional analysis method. To extend the application of these approaches to a range of natural surface conditions, the present study is to assess this approach by using both coastal shallow （RASEX） and open water surface measurements （Lake Ontario and Grand Banks ERS-1 SAR） where wind speeds were greater than 6.44 m s-1. Friction velocities, the surface aerodynamic roughness, and the neutral drag coefficient estimated by these approaches under moderate wind conditions were compared with the measurements mentioned above. Results showed that the coefficients in these approaches for coastal shallow water surface differ from those for open water surfaces, and that the aerodynamic roughness length in terms of wave age or significant wave height should be treated differently for coastal shallow and open water surfaces.

The influence of surface roughness on cloud cavitation flow around hydrofoils

The aim of this study is to investigate experimentally the effect of surface roughness on cloud cavitation around Clark-Y hydrofoils. High-speed video and particle image velocimetry(PIV) were used to obtain cavitation patterns images(Prog. Aerosp. Sci. 37: 551–581, 2001), as well as velocity and vorticity fields. Results are presented for cloud cavitating conditions around a Clark-Y hydrofoil fixed at angle of attack of α = 8? for moderate Reynolds number of Re = 5.6 × 10~5. The results show that roughness had a great influence on the pattern, velocity and vorticity distribution of cloud cavitation. For cavitating flow around a smooth hydrofoil(A) and a rough hydrofoil(B), cloud cavitation occurred in the form of finger-like cavities and attached subulate cavities, respectively. The period of cloud cavitation around hydrofoil A was shorter than for hydrofoil B.Surface roughness had a great influence on the process of cloud cavitation. The development of cloud cavitation around hydrofoil A consisted of two stages:(1) Attached cavities developed along the surface to the trailing edge;(2) A reentrant jet developed, resulting in shedding and collapse of cluster bubbles or vortex structure. Meanwhile, its development for hydrofoil B included three stages:(1) Attached cavities developed along the surface to the trailing edge, with accumulation and rotation of bubbles at the trailing edge of the hydrofoil affecting the flow field;(2) Development of a reentrant jet resulted in the first shedding of cavities. Interaction and movement of flows from the pressure side and suction side brought liquid water from the pressure side to the suction side of the hydrofoil, finally forming a reentrant jet. The jet kept moving along the surface to the leading edge of the hydrofoil, resulting in large-scale shedding of cloud bubbles. Several vortices appeared and dissipated during the process;(3) Cavities grew and shed again.

Tool Wear and Its Effect on Surface Roughness in Diamond Cutting of Glass Soda-lime

For the technology of diamond cutting of optical glass, the high tool wear rate is a main reason for hindering the practical application of this technology. Many researches on diamond tool wear in glass cutting rest on wear phenomenon describing simply without analyzing the genesis of wear phenomenon and interpreting the formation process of tool wear in mechanics. For in depth understanding of the tool wear and its effect on surface roughness in diamond cutting of glass, experiments of diamond turning with cutting distance increasing gradually are carried out on soda-lime glass. The wear morphology of rake face and flank face, the corresponding surface features of workpiece and the surface roughness, and the material compositions of flank wear area are detected. Experimental results indicate that the flank wear is predominant in diamond cutting glass and the flank wear land is characterized by micro-grooves, some smooth crater on the rake face is also seen. The surface roughness begins to increase rapidly, when the cutting mode changes from ductile to brittle for the aggravation of tool wear with the cutting distance over 150 m. The main mechanisms of inducing tool wear in diamond cutting of glass are diffusion, mechanical friction, thermo-chemical action and abrasive wear. The proposed research makes analysis and research from wear mechanism on the tool wear and its effect on surface roughness in diamond cutting of glass, and provides theoretical basis for minimizing the tool wear in diamond cutting brittle materials, such as optical glass.

Modeling and Evaluating of Surface Roughness Prediction in Micro-grinding on Soda-lime Glass Considering Tool Characterization

The current research of micro-grinding mainly focuses on the optimal processing technology for different materials. However, the material removal mechanism in micro-grinding is the base of achieving high quality processing surface. Therefore, a novel method for predicting surface roughness in micro-grinding of hard brittle materials considering micro-grinding tool grains protrusion topography is proposed in this paper. The differences of material removal mechanism between convention grinding process and micro-grinding process are analyzed. Topography characterization has been done on micro-grinding tools which are fabricated by electroplating. Models of grain density generation and grain interval are built, and new predicting model of micro-grinding surface roughness is developed. In order to verify the precision and application effect of the surface roughness prediction model proposed, a micro-grinding orthogonally experiment on soda-lime glass is designed and conducted. A series of micro-machining surfaces which are 78 nm to 0.98 ~tm roughness of brittle material is achieved. It is found that experimental roughness results and the predicting roughness data have an evident coincidence, and the component variable of describing the size effects in predicting model is calculated to be 1.5x 107 by reverse method based on the experimental results. The proposed model builds a set of distribution to consider grains distribution densities in different protrusion heights. Finally, the characterization of micro-grinding tools which are used in the experiment has been done based on the distribution set. It is concluded that there is a significant coincidence between surface prediction data from the proposed model and measurements from experiment results. Therefore, the effectiveness of the model is demonstrated. This paper proposes a novel method for predicting surface roughness in micro-grinding of hard brittle materials considering micro-grinding tool grains protrusion topography, which would provide significant research theory and experimental reference of material removal mechanism in micro-grinding of soda-lime glass.

Surface Roughness and Roundness of Bearing Raceway Machined by Floating Abrasive Polishing and Their Effects on Bearing's Running Noise

As the two most important indexes of bearing raceway, surface roughness and roundness have significant influence on bearing noise. Some researchers have carried out studies in this field, however, reason and extent of the influence of raceway surface geometric characteristics on bearing running noise are not perfectly clear up to now. In this paper, the raceway of 6309 type bearing＇s inner and outer ring is machined by floating abrasive polishing adopting soft abrasive pad. Surface roughness parameters, arithmetical mean deviation of the profile Ra, the point height of irregularities Rz, maximum height of the profile Rmax and roundness fof raceways, are measured before and after machining, and the change rules of the measured results are studied. The study results show that the floating abrasive polishing can reduce the surface geometric errors of bearing raceway evidently. The roundness error is reduced by 25%, Rm^x value is reduced by 35.5%, Rz value is reduced by 22% and Ra value is reduced by 5%. By analyzing the change of the geometrical parameters and the shape difference of the raceway before and after machining, it is found that the floating abrasive polishing method can affect the roundness error mainly by modifying the local deviation of the raceway＇s surface profile. Bearings with different raceway surface geometrical parameter value are assembled and the running noise is tested. The test results show that Ra has a little, Rmax and Rz have a measurable, and the roundness error has a significant influence on the running noise. From the viewpoint of controlling bearings＇ running noise, raceway roundness error should be strictly controlled, and for the surface roughness parameters, R,n^x and Rz should be mainly controlled. This paper proposes an effective method to obtain the low noise bearing by machining the raceway with floating abrasive polishing after super finishing.

Influence of Minimum Quantity Lubrication Parameters on Tool Wear and Surface Roughness in Milling of Forged Steel

The minimum quantity of lubrication（MQL） technique is becoming increasingly more popular due to the safety of environment.Moreover,MQL technique not only leads to economical benefits by way of saving lubricant costs but also presents better machinability.However,the effect of MQL parameters on machining is still not clear,which needs to be overcome.In this paper,the effect of different modes of lubrication,i.e.,conventional way using flushing,dry cutting and using the minimum quantity lubrication（MQL） technique on the machinability in end milling of a forged steel（50CrMnMo）,is investigated.The influence of MQL parameters on tool wear and surface roughness is also discussed.MQL parameters include nozzle direction in relation to feed direction,nozzle elevation angle,distance from the nozzle tip to the cutting zone,lubricant flow rate and air pressure.The investigation results show that MQL technique lowers the tool wear and surface roughness values compared with that of conventional flood cutting fluid supply and dry cutting conditions.Based on the investigations of chip morphology and color,MQL technique reduces the cutting temperature to some extent.The relative nozzle-feed position at 120°,the angle elevation of 60° and distance from nozzle tip to cutting zone at 20 mm provide the prolonged tool life and reduced surface roughness values.This fact is due to the oil mists can penetrate in the inner zones of the tool edges in a very efficient way.Improvement in tool life and surface finish could be achieved utilizing higher oil flow rate and higher compressed air pressure.Moreover,oil flow rate increased from 43.8 mL？h to 58.4 mL？h leads to a small decrease of flank wear,but it is not very significant.The results obtained in this paper can be used to determine optimal conditions for milling of forged steel under MQL conditions.