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.

Effect of Surface Roughness on Lubrication Performance of Bump-Type Gas Foil Bearings

Taking bump-type gas foil bearings as the research object,a deformation model of bump foil and a thin-plate finite element model of top foil were proposed.By solving Reynolds equation and energy equation,the pressure distribution and the temperature distribution of gas films in foil bearings were obtained.Further,a numerical method for calculating the lubrication performance of gas foil bearings with considering the surface roughness was proposed.With a specific example,effects of the surface roughness on the bearing lubrication performance were parametrically studied.The results indicate that rougher journal surface can lead to larger fluctuation of the lubrication performance,while surface roughness of top foil has few effects on the fluctuation.Moreover,the mean values of performance parameters almost remain constant at different values of surface roughness.

Impact of surface roughness,surface charge,and temperature on sandstone wettability alteration by nanoparticles

The wettability of rocks affects the balance between capillary and viscous forces during multiphase flow through porous media,which in turn determines the fluid displacement process governing the recovery of oil from subsurface formations.In this work,the mechanism of wettability reversal of aged synthetic sandstones by metal oxide nanoparticles(SiO_(2) and Al_(2)O_(3))was investigated with particular focus on the impact of surface roughness,zeta potential,and temperature.The synthetic surfaces were prepared from powders of Berea sandstone with known grain size ranges and their average roughness and roughness ratio were obtained from the 3D surface reconstruction of their microscope images.Each surface was subsequently aged in Permian crude oil to alter its wettability.For surfaces with larger grain sizes and lower surface roughness ratios,the lower capillary pressure allowed stronger oil/surface interactions,leading to enhanced oil-wetness.The wettability alteration effects of nanoparticles were then examined through real-time top view imaging and dynamic front view contact angle experiments.The negatively charged SiO_(2) nanoparticles rapidly reversed the sandstone wettability,indicating their potential applicability as wettability alteration agents.By contrast,the positively charged Al_(2)O_(3) counterpart caused no wettability reversal.The mechanism of wettability alteration was further studied by microscale interaction analyses and nanoscale transmission electron microscopy.Because nanoparticles were only a few nanometers large,the microscale roughness had a negligible effect on the wettability reversal.Instead,the combined effect of van der Waals dispersion forces and surface-charge-induced electrostatic forces were recognized as the two key factors affecting the wettability of sandstone particles.Such interactions may be curbed at elevated temperatures due to a decrease in the zeta potential and colloidal stability of the particles.

Evaluation of Surface Roughness of Aluminum Alloy in Burnishing Process Based on Chaos Theory

Burnishing experiments with different burnishing parameters were performed on a computer numerical control milling machine to characterize the surface roughness of an aluminum alloy during burnishing.The chaos theory was employed to investigate the nonlinear features of the burnishing system.The experimental results show that the power spectrum is broadband and continuous,and the Lyapunov exponentλis positive,proving that burnishing has chaotic characteristics.The chaotic characteristic parameter,the correlation dimension D,is sensitive to the time behavior of the system and is used to establish the corresponding relationship with the surface roughness.The correlation dimension was the largest,when the surface roughness was the smallest.Furthermore,when the correlation dimension curve decreases,the roughness curve increases.The correlation dimension and surface roughness exhibit opposite variation trends.The higher the correlation dimension,the lower the surface roughness.The surface roughness of the aluminum alloy can be characterized online by calculating the correlation dimension during burnishing.

Effects of surface roughness on bending properties of rolled AZ31 alloy

This study investigated the effects of mechanical-polishing-induced surface roughness and the direction of polishing lines on the bending properties of a rolled AZ31 alloy.To this end,three-point bending tests were performed on one sample without polishing lines(SS sample)and two samples with polishing lines—one in which the polishing lines were parallel to the rolling direction(RS-RD sample)and the other in which they were parallel to the transverse direction(RS-TD sample).In all three samples,macrocracks were formed in the width direction on the outer surface,where tensile stress was predominantly generated in the longitudinal direction.However,the macrocracks formed in the SS sample were curved because of the merging of uniformly formed fine microcracks,whereas those formed in the RS-TD sample were linear owing to the formation of relatively coarse microcracks along the polishing lines.The bendability of the samples was in the order of SS>RS-RD>RS-TD,and their limiting bending depths were 4.8,4.6,and 4.4 mm,respectively.In the presence of mechanical-polishing-induced surface roughness,polishing lines perpendicular to the direction of the major stress(i.e.,tensile stress along the longitudinal direction)resulted in a greater degree of stress concentration on the outer surface of the bending specimen.This higher stress concentration promoted the formation of undesirable{10–11}contraction and{10–11}–{10–12}double twins—which typically act as crack initiation sites—and thereby facilitated crack generation and propagation.Consequently,the surface roughness caused premature fracture during bending deformation,which,in turn,caused deterioration of the bendability of the rolled Mg alloy.

A theoretical and deep learning hybrid model for predicting surface roughness of diamond-turned polycrystalline materials

Polycrystalline materials are extensively employed in industry.Its surface roughness significantly affects the working performance.Material defects,particularly grain boundaries,have a great impact on the achieved surface roughness of polycrystalline materials.However,it is difficult to establish a purely theoretical model for surface roughness with consideration of the grain boundary effect using conventional analytical methods.In this work,a theoretical and deep learning hybrid model for predicting the surface roughness of diamond-turned polycrystalline materials is proposed.The kinematic–dynamic roughness component in relation to the tool profile duplication effect,work material plastic side flow,relative vibration between the diamond tool and workpiece,etc,is theoretically calculated.The material-defect roughness component is modeled with a cascade forward neural network.In the neural network,the ratio of maximum undeformed chip thickness to cutting edge radius RT S,work material properties(misorientation angle θ_(g) and grain size d_(g)),and spindle rotation speed n s are configured as input variables.The material-defect roughness component is set as the output variable.To validate the developed model,polycrystalline copper with a gradient distribution of grains prepared by friction stir processing is machined with various processing parameters and different diamond tools.Compared with the previously developed model,obvious improvement in the prediction accuracy is observed with this hybrid prediction model.Based on this model,the influences of different factors on the surface roughness of polycrystalline materials are discussed.The influencing mechanism of the misorientation angle and grain size is quantitatively analyzed.Two fracture modes,including transcrystalline and intercrystalline fractures at different RTS values,are observed.Meanwhile,optimal processing parameters are obtained with a simulated annealing algorithm.Cutting experiments are performed with the optimal parameters,and a flat surface finish with Sa 1.314 nm is finally achieved.The developed model and corresponding new findings in this work are beneficial for accurately predicting the surface roughness of polycrystalline materials and understanding the impacting mechanism of material defects in diamond turning.

Unraveling the influence of surface roughness on oil displacement by Janus nanoparticles

Janus nanoparticles(JNPs)possess great potential in recovering the residual oil from reservoirs,however,the fundamental interaction mechanisms among nanoparticles,the oil,and reservoir wall characteristics remain to be elucidated.In this work,models of oil trapping grooves with different geometric features are subjected to molecular dynamics simulations for investigating the influences of roughness parameters on oil displacement dynamics by JNPs.Four key surface geometry parameters and different degrees of surface hydrophobicity are considered.Our results indicate that JNPs hold an outstanding performance in displacing residual oil on weakly to moderately hydrophobic surfaces.Overall,smaller entry and exit angles,the larger aspect ratio of the oil trapping grooves,and a bigger tip length of the rough ridges lead to superior oil recovery.Among the key geometric parameters,the aspect ratio of the oil trapping grooves plays the dominant role.These insights about the interaction of surface properties and JNPs and the resulting trapped oil displacement could serve as a theoretical reference for the application of JNPs for targeted reservoir conditions.

Triboelectric‘electrostatic tweezers'for manipulating droplets on lubricated slippery surfaces prepared by femtosecond laser processing

The use of‘Electrostatic tweezers'is a promising tool for droplet manipulation,but it faces many limitations in manipulating droplets on superhydrophobic surfaces.Here,we achieve noncontact and multifunctional droplet manipulation on Nepenthes-inspired lubricated slippery surfaces via triboelectric electrostatic tweezers(TETs).The TET manipulation of droplets on a slippery surface has many advantages over electrostatic droplet manipulation on a superhydrophobic surface.The electrostatic field induces the redistribution of the charges inside the neutral droplet,which causes the triboelectric charged rod to drive the droplet to move forward under the electrostatic force.Positively or negatively charged droplets can also be driven by TET based on electrostatic attraction and repulsion.TET enables us to manipulate droplets under diverse conditions,including anti-gravity climb,suspended droplets,corrosive liquids,low-surface-tension liquids(e.g.ethanol with a surface tension of 22.3 mN·m^(-1)),different droplet volumes(from 100 nl to 0.5 ml),passing through narrow slits,sliding over damaged areas,on various solid substrates,and even droplets in an enclosed system.Various droplet-related applications,such as motion guidance,motion switching,droplet-based microreactions,surface cleaning,surface defogging,liquid sorting,and cell labeling,can be easily achieved with TETs.

Precipitates Generation Mechanism and Surface Quality Improvement for Aluminum Alloy 6061 in Diamond Cutting

To improve the surface quality for aluminum alloy 6061(Al6061) in ultra-precision machining, we investigated the factors affecting the surface finish in single point diamond turning(SPDT)by studying influence of the precipitates generation of Al6061 on surface integrity and surface roughness.Based on the Johnson-Mehl-Avrami solid phase transformation kinetics equation, theoretical and experimental studies were conducted to build the relationship between the aging condition and the type, size and number of the precipitates for Al6061. Diamond cutting experiments were conducted to machine Al6061 samples under different aging conditions. The experimental results show that, the protruding on the chip surface is mainly Mg_(2)Si and the scratches on the machined surface mostly come from the iron-containing phase(α-, β-AlFeSi).Moreover, the generated Mg_(2)Si and α-, β-AlFeSi affect the surface integrity and the diamond turned surface roughness. Especially, the achieved surface roughness in SPDT is consistent with the variation of the number of AlFeSi and Mg_(2)Si with the medium size(more than 1 μm and less than 2 μm) in Al6061.

Influence of Input Factors on Surface Roughness and Material Removal Speed when Wire-EDM a Hardened SKD11 Steel Curve Profile

The goal of this research is to identify the best set of process machining parameters for wire-EDM(Electrical Discharge Machining)cutting of hardened SKD11 steel when machining a curve profile.The multi-objective function includes reducing surface roughness and increasing MRR(Material Removal Rate).The optimization process is prepared by using Taguchi method coupled Grey Relational Analysis.The obtained results revealed that Toff has the greatest influence on the average grey value(48.30%),followed by the influence of WF(Wire Feed,15.99%),VM(Cutting Voltage,9.33%),SV(Server Voltage,5.05%),Ton(Pulse on Time,1.81%),while SPD(Cutting Speed)has a negligible effect(0.89%).Moreover,using the optimal set of machining parameters generates in surface roughness of 1.25399mm and MRR of 26.5562 mm^(2)/min.The verification experiment and Anderson-Darling method demonstrate the validity of the proposed model,which can be utilized for estimating surface roughness and MRR.

A facile strategy for tuning the density of surface-grafted biomolecules for melt extrusion-based additive manufacturing applications

Melt extrusion-based additive manufacturing(ME-AM)is a promising technique to fabricate porous scaffolds for tissue engi-neering applications.However,most synthetic semicrystalline polymers do not possess the intrinsic biological activity required to control cell fate.Grafting of biomolecules on polymeric surfaces of AM scaffolds enhances the bioactivity of a construct;however,there are limited strategies available to control the surface density.Here,we report a strategy to tune the surface density of bioactive groups by blending a low molecular weight poly(ε-caprolactone)5k(PCL5k)containing orthogonally reactive azide groups with an unfunctionalized high molecular weight PCL75k at different ratios.Stable porous three-dimensional(3D)scaf-folds were then fabricated using a high weight percentage(75 wt.%)of the low molecular weight PCL 5k.As a proof-of-concept test,we prepared films of three different mass ratios of low and high molecular weight polymers with a thermopress and reacted with an alkynated fluorescent model compound on the surface,yielding a density of 201-561 pmol/cm^(2).Subsequently,a bone morphogenetic protein 2(BMP-2)-derived peptide was grafted onto the films comprising different blend compositions,and the effect of peptide surface density on the osteogenic differentiation of human mesenchymal stromal cells(hMSCs)was assessed.After two weeks of culturing in a basic medium,cells expressed higher levels of BMP receptor II(BMPRII)on films with the conjugated peptide.In addition,we found that alkaline phosphatase activity was only significantly enhanced on films contain-ing the highest peptide density(i.e.,561 pmol/cm^(2)),indicating the importance of the surface density.Taken together,these results emphasize that the density of surface peptides on cell differentiation must be considered at the cell-material interface.Moreover,we have presented a viable strategy for ME-AM community that desires to tune the bulk and surface functionality via blending of(modified)polymers.Furthermore,the use of alkyne-azide“click”chemistry enables spatial control over bioconjugation of many tissue-specific moieties,making this approach a versatile strategy for tissue engineering applications.

An ensemble learning method to retrieve sea ice roughness from Sentinel-1 SAR images

Sea ice surface roughness(SIR)affects the energy transfer between the atmosphere and the ocean,and it is also an important indicator for sea ice characteristics.To obtain a small-scale SIR with high spatial resolution,a novel method is proposed to retrieve SIR from Sentinel-1 synthetic aperture radar(SAR)images,utilizing an ensemble learning method.Firstly,the two-dimensional continuous wavelet transform is applied to obtain the spatial information of sea ice,including the scale and direction of ice patterns.Secondly,a model is developed using the Adaboost Regression model to establish a relationship among SIR,radar backscatter and the spatial information of sea ice.The proposed method is validated by using the SIR retrieved from SAR images and comparing it to the measurements obtained by the Airborne Topographic Mapper(ATM)in the summer Beaufort Sea.The determination of coefficient,mean absolute error,root-mean-square error and mean absolute percentage error of the testing data are 0.91,1.71 cm,2.82 cm,and 36.37%,respectively,which are reasonable.Moreover,K-fold cross-validation and learning curves are analyzed,which also demonstrate the method’s applicability in retrieving SIR from SAR images.

High-order Bragg forward scattering and frequency shift of low-frequency underwater acoustic field by moving rough sea surface

Acoustic scattering modulation caused by an undulating sea surface on the space-time dimension seriously affects underwater detection and target recognition.Herein,underwater acoustic scattering modulation from a moving rough sea surface is studied based on integral equation and parabolic equation.And with the principles of grating and constructive interference,the mechanism of this acoustic scattering modulation is explained.The periodicity of the interference of moving rough sea surface will lead to the interference of the scattering field at a series of discrete angles,which will form comb-like and frequency-shift characteristics on the intensity and the frequency spectrum of the acoustic scattering field,respectively,which is a high-order Bragg scattering phenomenon.Unlike the conventional Doppler effect,the frequency shifts of the Bragg scattering phenomenon are multiples of the undulating sea surface frequency and are independent of the incident sound wave frequency.Therefore,even if a low-frequency underwater acoustic field is incident,it will produce obvious frequency shifts.Moreover,under the action of ideal sinusoidal waves,swells,fully grown wind waves,unsteady wind waves,or mixed waves,different moving rough sea surfaces create different acoustic scattering processes and possess different frequency shift characteristics.For the swell wave,which tends to be a single harmonic wave,the moving rough sea surface produces more obvious high-order scattering and frequency shifts.The same phenomena are observed on the sea surface under fully grown wind waves,however,the frequency shift slightly offsets the multiple peak frequencies of the wind wave spectrum.Comparing with the swell and fully-grown wind waves,the acoustic scattering and frequency shift are not obvious for the sea surface under unsteady wind waves.

Shear behaviours and roughness degeneration based on a quantified rock joint surface description

The asperity wear of rock joints significantly affects their shear behaviour.This study discusses the wear damage of the asperities on the joint surface,highlighting the roughness degradation characteristics during the shear process.The direct shear experiment of artificial specimens containing rock joints was conducted under different normal stresses based on three-dimensional scanning technology.These experimental results showed the contribution of joint wear to roughness degeneration,such as the height,zone,and volume of asperity degeneration.The wear coefficient of the rock joint was obtained based on the volume wear of asperities in the laboratory experiment.The functional relationship between the friction coefficient and wear coefficient is subsequently determined.To quantitatively analyse the wear damage of a joint surface,a calculation method for determining the wear depth of the rock joint after shearing was proposed based on wear theory.The relationship between the ultimate dilation and wear depth was analysed.A coefficient m,which can describe the damage degree of the joint surface,and a prediction method of joint surface roughness after shearing are established.Good agreement between analytical predictions and measured values demonstrates the capability of the developed model.Lastly,the sensitivity factors on the wear depth are explored.

Influence of surface roughness on the development of moss-dominated biocrusts on mountainous rock-cut slopes in West Sichuan, China

Since natural restoration combined with artificial auxiliary measures may achieve a relatively rapid restoration effect at a lower cost, it has become an essential measure for the ecological restoration of rock slopes. Previous studies have focused heavily on the relationship between substrate nutrients and water conditions and the development of mosses on the rock surface, but quantitative characterization of substantial effect of rock surface texture(e.g., microrelief) on moss growth is absent. The undulating microrelief on the rock surface can increase the heterogeneity of the microhabitat, which may be an important factor affecting the development of mossdominated biocrusts. In this study, the roughness of rock surfaces, moss coverage and biomass, weight and major nutrient contents of soils within the biocrusts were measured in the western mountainous area of Sichuan Province, Southwest China to further examine the role of rock surface microrelief in the biocrusts. The results showed that three main factors affecting the development of the biocrusts were bryophyte emergence, soil accumulation, and lithology. The presence of moss accelerates soil formation on rock surfaces and lead to the accumulation of nutrients so that all parts of the moss-dominated biocrusts system can develop synergistically. It was found that a microrelief structure with a roughness between 1.5 and 2.5 could gather soil and bryophyte propagules effectively, which may have a strong relationship with the angle of repose. When the roughness is 1.5, the corresponding undulation angle is very close to the theoretical minimum value of the undulation angle calculated according to the relationships between the undulation angle of the protrusion, slope and angle of repose.

Surface Metallization of Glass Fiber(GF)/Polyetheretherketone(PEEK) Composite with Cu Coatings Deposited by Magnetron Sputtering and Electroplating

Surface metallization of glass fiber(GF)/polyetheretherketone(PEEK)[GF/PEEK] is conducted by coating copper using electroplating and magnetron sputtering and the properties are determined by X-ray diffraction(XRD), scanning electron microscopy(SEM), and electron backscatter diffraction(EBSD).The coating bonding strength is assessed by pull-out tests and scribing in accordance with GB/T 9286-1998.The results show that the Cu coating with a thickness of 30 μm deposited on GF/PEEK by magnetron sputtering has lower roughness, finer grain size, higher crystallinity, as well as better macroscopic compressive stress,bonding strength, and electrical conductivity than the Cu coating deposited by electroplating.

A consecutive joint shear strength model considering the 3D roughness of real contact joint surface

A consecutive joint shear strength model for soft rock joints is proposed in this paper,which takes into account the degradation law of the actual contact three-dimensional(3D)roughness.The essence of the degradation of the maximum possible dilation angle is the degradation of the 3D average equivalent dip angle of the actual contact joint asperities.Firstly,models for calculating the maximum possible dilation angle at the initial and residual shear stress stages are proposed by analyzing the 3D joint morphology characteristics of the corresponding shear stages.Secondly,the variation law of the maximum possible dilation angle is quantified by studying the degradation law of the joint micro convex body.Based on the variation law of the maximum possible dilation angle,the maximum possible shear strength model is proposed.Furthermore,a method to calculate the shear stiffness degradation in the plastic stage is proposed.According to the maximum possible shear strength of rock joints,the shear stress-shear displacement prediction model of rock joints is obtained.The new model reveals that there is a close relationship between joint shear strength and actual contact joint roughness,and the degradation of shear strength after the peak is due to the degradation of actual contact joint roughness.

Pulses in ground motions identified through surface partial matching and their impact on seismic rocking consequence

In seismology and earthquake engineering,it is fundamental to identify and characterize the pulse-like features in pulse-type ground motions.To capture the pulses that dominate structural responses,this study establishes congruence and shift relationships between response spectrum surfaces.A similarity search between spectrum surfaces,supplemented with a similarity search in time series,has been applied to characterize the pulse-like features in pulse-type ground motions.The identified pulses are tested in predicting the rocking consequences of slender rectangular blocks under the original ground motions.Generally,the prediction is promising for the majority of the ground motions where the dominant pulse is correctly identified.