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 characteristics analysis of fractures induced by supercritical CO_(2)and water through three-dimensional scanning and scanning electron micrography

Morphology of hydraulic fracture surface has significant effects on oil and gas flow,proppant migration and fracture closure,which plays an important role in oil and gas fracturing stimulation.In this paper,we analyzed the fracture surface characteristics induced by supercritical carbon dioxide(SC-CO_(2))and water in open-hole and perforation completion conditions under triaxial stresses.A simple calculation method was proposed to quantitatively analyze the fracture surface area and roughness in macro-level based on three-dimensional(3D)scanning data.In micro-level,scanning electron micrograph(SEM)was used to analyze the features of fracture surface.The results showed that the surface area of the induced fracture increases with perforation angle for both SC-CO_(2)and water fracturing,and the surface area of SC-CO_(2)-induced fracture is 6.49%e58.57%larger than that of water-induced fracture.The fractal dimension and surface roughness of water-induced fractures increase with the increase in perforation angle,while those of SC-CO_(2)-induced fractures decrease with the increasing perforation angle.A considerable number of microcracks and particle peeling pits can be observed on SC-CO_(2)-induced fracture surface while there are more flat particle surfaces in water-induced fracture surface through SEM images,indicating that fractures tend to propagate along the boundary of the particle for SC-CO_(2)fracturing while water-induced fractures prefer to cut through particles.These findings are of great significance for analyzing fracture mechanism and evaluating fracturing stimulation performance.

Influence of roughness on the detection of mechanical characteristics of low-k film by the surface acoustic waves

The surface acoustic wave （SAW） technique is a precise and nondestructive method to detect the mechanical charac- teristics of the thin low dielectric constant （low-k） film by matching the theoretical dispersion curve with the experimental dispersion curve. In this paper, the influence of sample roughness on the precision of SAW mechanical detection is inves- tigated in detail. Random roughness values at the surface of low-k film and at the interface between this low-k film and the substrate are obtained by the Monte Carlo method. The dispersive characteristic of SAW on the layered structure with rough surface and rough interface is modeled by numerical simulation of finite element method. The Young＇s moduli of the Black DiamondTM samples with different roughness values are determined by SAWs in the experiment. The results show that the influence of sample roughness is very small when the root-mean-square （RMS） of roughness is smaller than 50 nm and correlation length is smaller than 20 μm. This study indicates that the SAW technique is reliable and precise in the nondestructive mechanical detection for low-k films.

Determination of Surface Roughness in Wire and Arc Additive Manufacturing Based on Laser Vision Sensing

Wire and arc additive manufacturing(WAAM) shows a great promise for fabricating fully dense metal parts by means of melting materials in layers using a welding heat source. However, due to a large layer height produced in WAAM, an unsatisfactory surface roughness of parts processed by this technology has been a key issue. A methodology based on laser vision sensing is proposed to quantitatively calculate the surface roughness of parts deposited by WAAM.Calibrations for a camera and a laser plane of the optical system are presented. The reconstruction precision of the laser vision system is verified by a standard workpiece. Additionally, this determination approach is utilized to calculate the surface roughness of a multi-layer single-pass thin-walled part. The results indicate that the optical measurement approach based on the laser vision sensing is a simple and effective way to characterize the surface roughness of parts deposited by WAAM. The maximum absolute error is less than 0.15 mm. The proposed research provides the foundation for surface roughness optimization with different process parameters.

Surface Characteristics Measurement Using Computer Vision:A Review

Computer vision provides image-based solutions to inspect and investigate the quality of the surface to be measured.For any components to execute their intended functions and operations,surface quality is considered equally significant to dimensional quality.Surface Roughness(Ra)is a widely recognized measure to evaluate and investigate the surface quality of machined parts.Various conventional methods and approaches to measure the surface roughness are not feasible and appropriate in industries claiming 100%inspection and examination because of the time and efforts involved in performing the measurement.However,Machine vision has emerged as the innovative approach to executing the surface roughness measurement.It can provide economic,automated,quick,and reliable solutions.This paper discusses the characterization of the surface texture of surfaces of traditional or non-traditional manufactured parts through a computer/machine vision approach and assessment of the surface characteristics,i.e.,surface roughness,waviness,flatness,surface texture,etc.,machine vision parameters.This paper will also discuss multiple machine vision techniques for different manufacturing processes to perform the surface characterization measurement.

Three-dimensional Monte Carlo simulation of bulk fin field effect transistor

In this paper, we investigate the performance of the bulk fin field effect transistor （FinFET） through a three- dimensional （3D） full band Monte Carlo simulator with quantum correction. Several scattering mechanisms, such as the acoustic and optical phonon scattering, the ionized impurity scattering, the impact ionization scattering and the surface roughness scattering are considered in our simulator. The effects of the substrate bias and the surface roughness scattering near the Si/SiO2 interface on the performance of bulk FinFET are mainly discussed in our work. Our results show that the on-current of bulk FinFET is sensitive to the surface roughness and that we can reduce the substrate leakage current by modulating the substrate bias voltage.

Investigation on surface roughness,residual stress and fatigue property of milling in-situ TiB_2/7050Al metal matrix composites

For higher efficiency and precision manufacturing,more and more attentions are focused on the surface roughness and residual stress of machined parts to obtain a good fatigue life.At present,the in-situ TiB_2/7050 Al metal matrix composites are widely researched due to its attractive properties such as low density,good wear resistance and improved strength.It is of great significance to investigate the machined surface roughness,residual stress and fatigue life for higher efficiency and precision manufacturing of this new kind material.In this study,the surface roughness including two-dimensional and three-dimensional roughness,residual stress and fatigue life of milling in-situ TiB_2/7050 Al metal matrix composites were analyzed.It was found from comparative investigation that the three-dimensional surface roughness would be more appropriate to represent the machined surface profile of milling particle reinforced metal matrix composites.The cutting temperature played a great role on the residual stress.However,the effect of increasing cutting force could slow down the transformation from compressive stress to tensile stress under 270°C.An exponential relationship between three-dimensional roughness and fatigue life was established and the main fracture mechanism was brittle fracture with observation of obvious shellfish veins,river pattern veins and wave shaped veins in fracture surface.

Surface morphology characterization of unidirectional carbon fibre reinforced plastic machined by peripheral milling

This paper aims to characterise surface morphology and 3D roughness parameters of unidirectional carbon fibre reinforced plastic(UD-CFRP)milled at 0°,45°,90°,and 135°fibre orientation angles(FOAs).Side milling experiments are conducted on UD-CFRP laminates.Surface damage forms and texture direction of milled surface are analysed.Spatial frequency of defects on CFRP surface is quantitatively determined using radially averaged 2D PSD.The kinematicdynamic surface topography is reconstructed considering feed,runout and vibration,then the ideal roughness parameters,S_(a),S_(q),S_(sk),and S_(ku)are calculated and compared with the measured ones,finally the material factor-induced roughness components are quantified.Results show that CFRP surface has no regular feed marks.The frequency of fibre breakage or surface defects is greater than tooth passing frequency.FOAs sorted by their average S_(a)in descending order is135°>90°>45°>0°,where surface defects contribute 93.9%,77.1%,73.2%,72.2%of the total roughness respectively,which suggests that surface defects show a more important role than tool kinematics and vibration in formation of milled surface.The negative Skewness(Ssk<0)and high Kurtosis(S_(ku)=4.0–11.5)of milled surface signify porosity and the presence of many anomalous deep valleys in milled surface,respectively.

高速互连PCB的材料电磁表征方法研究

随着数据传输速率的不断增加,对高速互连的信号完整性设计和优化变得至关重要。在高速通道设计的各个方面中,我们通过对现有的方法进行综述来着重介绍准确的PCB材料电磁表征这一关键问题,并对于提取PCB材料特性,如介电常数、损耗正切以及铜表面粗糙度的各种方法进行分类。首先,这些方法分为两大类:①对原始介质材料进行表征的技术;②适用于一般由玻璃纤维和树脂材料混合而成的PCB材料的表征方法。在每个类别中,简要描述了几种常用技术,并进行了优缺点的比较和讨论。基于传输线的方法的挑战和局限性在这里尤为重要,因为相关的材料特性提取程序在工业中已经是常规操作。此外,特别是在数十吉赫兹的频率范围内,典型铜箔表面粗糙度对准确材料表征的影响也被考虑。本文旨在通过总结和比较提供PCB材料表征方法的全面概述和分析。

3D粗糙表面的数字化表征与接触特性分析

为了研究粗糙表面的复杂接触力学行为,提出了一种关于微观两粗糙表面接触的有限元分析方法.通过3D粗糙表面的数字化表征方法,获得了具有不同统计特征的高斯或非高斯粗糙表面,在此基础上,通过自下而上的三维建模与六面体网格划分,构建了两粗糙表面接触的精细有限元分析模型.在不同法向载荷的作用下,分析了微观结合面的变形、接触压力、真实接触面积等接触特征及其加载卸载特性,揭示了结合面的力学行为规律,为微观粗糙表面的性能预测提供了一种有效的途径.

三维表面粗糙度的表征和应用

表面粗糙度会直接影响零部件的耐磨性、密封性以及抗腐蚀性等,是评定机械加工和产品质量的重要指标。现代科技水平的不断提高对零件表面性能的要求也日益严苛。传统的二维表面粗糙度的测量和表征已经不再能够满足技术发展的要求,三维表面粗糙度由于能够更加全面、真实地反映工件表面的状态而受到人们的重视,成为研究热点。本文回顾了三维表面粗糙度的发展历史,系统地介绍了三维表面粗糙度参数及标准的发展现状,分析了表面形貌与功能特性的联系,概述了三维粗糙度参数在制造业、生物医疗、摩擦学与材料科学等领域的广泛应用,并进一步指出了三维表面粗糙度表征和应用的发展方向。未来随着相关研究(比如,三维测量的溯源性、重复性、参数表征体系等问题)的深入以及三维表面测量手段的发展,三维表面粗糙度参数也将不断完善和推广,并更多地与实际功能相结合来预测并指导生产,确保工件的表面质量。

三维表面微观形貌的表征趋势

近几年计算能力、计算速度、图像分析、数据处理技术的不断提高 ,极大地推进了三维表面微观形貌测量仪的实用化和商品化。对最近文献中出现的三维分析方法和表征参数 ,如基准表面、图形 (像 )表征、参数表征以及图形和分形表征方法等进行了综述。

纳米尺度标准样片光学表征方法的研究

重点研究了纳米尺度标准样片的光学表征方法。采用基于纳米测量机(NMM)的激光聚焦传感器(LFS)和扫描白光干涉传感器(SWLIS)分别对平面尺度的标准样片和台阶标准样片进行了测量、分析与比较。实验结果表明,利用该纳米测量机LFS对标定值为3μm的TGZ1一维栅格样片进行测量,其扩展不确定度为4.2 nm,实现了精确表征。利用SWLIS测量方法对标定值为49.217μm的SHS8-50.0高台阶标准样板进行测量,测量不确定度分析结果为0.065 7μm,实现了采用光学检测技术跨尺度对纳米尺度精密器件和结构进行表征。扩大了基于纳米测量机光学表征方法的应用范围,有利于纳米几何量量值溯源体系的建立。

结构函数与均方根分形表征效果的比较

为了比较结构函数与均方根两种测度方法的分形表征效果,模拟了具有不同理论分形维数的Weierstrass-Mandelbrot分形轮廓曲线;制备了车削、磨削和砂纸打磨的不同粗糙表面,并提取了它们的轮廓曲线;然后用结构函数和均方根两种方法对理论和实际的轮廓曲线进行了分形表征和分维计算.研究表明,两种测度方法对分形模拟轮廓曲线均具有较好的表征效果;对于机加工粗糙表面,均方根测度方法比结构函数测度方法的适应性强,无标度区间宽,表征效果好;另外,均方根测度方法还具有物理意义明确,分维计算简单和分形表征直观等优点.

非均匀锈蚀钢筋表面轮廓的分形表征

通过NaCl溶液干湿循环对热轧光圆钢筋进行加速腐蚀,采用单尖头百分尺获取了不同锈蚀率钢筋的表面轮廓曲线,并对其进行统计分析与分形计算.结果表明,锈蚀钢筋的蚀坑呈不均匀分布特性,其表面轮廓直径符合正态分布,且具有统计分形的特征;但分形维数反映的是轮廓曲线的相似程度,对于轮廓曲线的微小变化并不敏感.通过特征轮廓参数r*将分形维数D与尺度系数C联系在一起,实现了表面多尺度相似测量与绝对测量的统一,该参数具有物理意义清晰且灵敏度高的特点,可用于钢筋不均锈蚀程度的表征.

两种测度方法表征粗糙表面的效果研究

为了比较结构函数与均方根2种测度方法对粗糙表面的分形表征效果,模拟了具有不同理论分形维数的表面轮廓曲线,然后用结构函数和均方根2种方法对它们进行分形特性表征和分形维数计算,并对表征结果进行了理论分析。研究表明,2种测度方法均具有较好的表征效果。与结构函数测度方法相比,均方根测度方法的分维计算精度高,表征曲线的线性度好,反映分形特征的无标度区间宽,分形表征效果显著。另外,均方根测度方法还具有物理意义明确和分维计算简单的优点。因此均方根测度方法不失为粗糙表面分形表征的一种有效方法。

小波变换在粗糙表面几何形貌表征中的应用

粗糙表面几何形貌对于表面特性如摩擦、磨损、润滑、腐蚀疲劳等具有重大的影响,表面几何形貌能否及时准确地被表征具有重要的工程意义.简要叙述小波变换的特点,重点介绍目前小波变换在表面粗糙度评定、表面形貌分离与重构以及表面形貌分形维数提取等方面的应用,提出了目前小波变换在表面几何形貌表征中存在的不足,以及今后小波技术在表面形貌中发展的新趋势.

面向功能的表面形貌Motif表征研究

简述了现代工业对表面功能特性的新要求,表面形貌具有保证产品品质和功能的双重性,面向功能的表面形貌表征是实现表面设计与评定的基础;介绍了表面形貌的二维Motif表征及其评定参数;分析了不同的Motif评定参数对各种表面功能的对应表征关系;概述了三维Motif方法的定义和评定参数;提出了对表面形貌进行评定需要注意的问题。

用高阶矩谱表征粗糙表面的偏斜程度

基于双谱分析理论,结合表面粗糙度偏斜度参数的定义,提出了偏斜度函数的表达方式,以及二维双谱的对角线切片算法,并将它们用于三维粗糙工程表面的偏斜度描述。文中还对具有对称、正偏态和负偏态分布特征的电火花、精密车削和研磨加工试件进行了实验研究,认为双谱和偏斜度函数可以合理有效地描述三维粗糙表面偏离高斯分布的程度。

基于形貌参数表征系统的表面粗糙度评定实验平台开发

随着对机械零部件表面质量要求的不断提高,需要更准确有效地表征表面形貌参数。本文采用VC++软件,研制了一套适用于表面形貌粗糙度参数表征及研究的系统,可以用于互换性与测量技术基础等课程中表面粗糙度监测与评定实验,也可以用于表面形貌参数表征及其表面性能等方面的研究。本系统主要包括了表面形貌轮廓曲线的绘制、各种表面粗糙度参数的计算和比较等。