New advancement of technology and never satisfying demands of the civilization are putting huge pressure on the natural fuel resources and these resources are at a constant threat to its sustainability. Surface finish has a vital influence on functional properties such as wear resistance and power loss due to friction on most of the engineering components. Voltage, mesh number, revolutions per minute (rpm) of electromagnet, and percentage weight of abrasives has been identified as important process parameters affecting surface roughness. The experiments were planned using response surface methodology and percentage change in surface roughness (ΔRa) was considered as response. Analysis of experimental data showed that percentage change in surface roughness (ΔRa) was highly influenced by mesh number followed by percentage weight of abrasives, rpm of electromagnet, and voltage. The process has been investigated extensively in the finishing of cylindrical surfaces. The surface finish was found to improve significantly with an increase in the grain size, relative size of abrasive particles vis-à-vis the iron particles, feed rate and current. Super finishing is a micro-finishing process that produces a controlled and smooth surface condition on work pieces. It is not primarily a sizing operation, its major purpose is to produce a surface on a work piece capable of sustaining uneven distribution of a load by improving the geometrical accuracy. The wear life of the parts micro finished to maximum smoothness is extended considerably. According to the design of experimentation, mathematical model for Lapping operation on advance ceramic material is proposed. In order to get minimum values of the surface roughness, optimization of the mathematical model is done and optimal operation of the examined factors is going to be determined. The obtained res
Experimental Investigations on Tribiological Properties of 6061-T6 Al Alloy b...IJAEMSJORNAL
Microstructure and tribological properties of Al-TiB2 nano surface composite fabricated by Friction Stir Processing (FSP) were evaluated. To vary the percentage of TiB2 three different slot thickness viz. 1mm, 1.5 mm and 2mm were considered. Microstructural evaluations showed a nearly uniform distribution of TiB2 in the aluminium matrix after FSP with the addition of composite powder. Microhardness test results shoes FSW of Al6061-T6 alloy with 2mm groove width has more hardness. tribological properties were evaluated at two different sliding velocities 0.314m/s and 0.48m/s and results shows that at lower loads there is no much difference in wear rate of surface composite made with different slot sizes but with increase in load and sliding velocity wear rate was increased , however, larger slot Al6061-TiB2 Surface composites show better wear resistance.
Manufacturing of Surface Composite Al6351/SIC Using Friction Stir ProcessingIJSRD
Friction stir welding (FSW) is a relatively new solid-state joining process. This joining technique is energy efficient, environment friendly, and versatile. In particular, it can be used to join high-strength aerospace aluminum alloys and other metallic alloys that are hard to weld by conventional fusion welding. FSW is considered to be the most significant development in metal joining in a decade. Recently, friction stir processing (FSP) was developed for microstructural modification of metallic materials. In this study, SiC particles and Methanol paste were incorporated by using Friction Stir Processing (FSP) into the 6351 aluminum alloy to form particulate composite materials. Samples were subjected to traverse speeds of the FSP tool with and without Paste (SiC+ Methanol). Microstructural observations were carried out by employing optical microscopy of the modified surfaces. For the 100% overlapping, No. of passes caused grain modification in the processed zone.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Experimental Investigations on Tribiological Properties of 6061-T6 Al Alloy b...IJAEMSJORNAL
Microstructure and tribological properties of Al-TiB2 nano surface composite fabricated by Friction Stir Processing (FSP) were evaluated. To vary the percentage of TiB2 three different slot thickness viz. 1mm, 1.5 mm and 2mm were considered. Microstructural evaluations showed a nearly uniform distribution of TiB2 in the aluminium matrix after FSP with the addition of composite powder. Microhardness test results shoes FSW of Al6061-T6 alloy with 2mm groove width has more hardness. tribological properties were evaluated at two different sliding velocities 0.314m/s and 0.48m/s and results shows that at lower loads there is no much difference in wear rate of surface composite made with different slot sizes but with increase in load and sliding velocity wear rate was increased , however, larger slot Al6061-TiB2 Surface composites show better wear resistance.
Manufacturing of Surface Composite Al6351/SIC Using Friction Stir ProcessingIJSRD
Friction stir welding (FSW) is a relatively new solid-state joining process. This joining technique is energy efficient, environment friendly, and versatile. In particular, it can be used to join high-strength aerospace aluminum alloys and other metallic alloys that are hard to weld by conventional fusion welding. FSW is considered to be the most significant development in metal joining in a decade. Recently, friction stir processing (FSP) was developed for microstructural modification of metallic materials. In this study, SiC particles and Methanol paste were incorporated by using Friction Stir Processing (FSP) into the 6351 aluminum alloy to form particulate composite materials. Samples were subjected to traverse speeds of the FSP tool with and without Paste (SiC+ Methanol). Microstructural observations were carried out by employing optical microscopy of the modified surfaces. For the 100% overlapping, No. of passes caused grain modification in the processed zone.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
IMPROVING OPTIMIZED THE SURFACE QUALITY OF STAINLESS STEEL JIS 440 ON LAPPING...IAEME Publication
This objective of research was studied to study lapping process for achieving high quality alumina the surface quality of stainless steel JIS 440 on lapping process. Factorial experiment was applied to analyze the four-alumina powder size of 0.3 µm and nine-lapping time of 30, 60, 90, 120, 150, 180, 210, 240 and 270 min, respectively. In preparing of specimen surface roughness for experimental, was used the ratio between the alumina powder of 200 g, alumina powder lubricant of 150 ml and water of 1 l which has Five surface roughness values, Ra were then prepared: 0.4 μm, 0.8 μm, 1.2 μm, 1.6 μm and 2.0 μm, respectively. Alumina abrasive powder size of 0.3 µm at a surface roughness of Ra 0.8 µm at 30 min resulted in the best average surface roughness (Ra) of 0.0575 µm when considering the satisfaction value. (Desirability: D) with regard to statistical processing, it was found that the value was as high as 99.37% Correlation of surface quality with lapping parameters was established to achieve process optimization.
Effect of silicon carbide percentage on fracture toughness of aluminium silio...eSAT Journals
Abstract Metal matrix composites are composites in which one component will be a metal and other metal or non metal. It has wide applications in various fields like automobile, turbines blades etc which needs good mechanical properties. This thesis work studies about Aluminium Silicon Carbide metal matrix composites and their properties. Earlier studies revealed that as the percentage of Silicon Carbide is increased the properties get increased up to a limit and fracture toughness gets reduced beyond that. Here, in this work different percentage of SiC is added and fracture toughness is analyzed in terms of Stress intensity factor since fracture toughness cannot be calculated directly. Both software simulation and experimental methods has been done to find out the best percentage composition. Keywords: Metal matrix composites, Aluminium Silicon Carbide, Fracture Toughness, Stress Intensity Factor
Diamond turning is an ultraprecision machining technology for the generation of complex functional surfaces and extremely fine microstructures with the use of geometrically defined diamond cutters.
The cutters can be natural diamond or synthetic diamond depending finishing scale of machining and finishing requirements.
Diamond turn machining is a well-established and affordable process for the fabrication of highly accurate optical components as well as mechanical components requiring micro inch dimensional tolerances.
Diamond turning is used primarily to manufacture ultra precision parts for advanced applications, those that call for extremely high levels of form accuracy and surface finishing.
Casting Defects Analysis in Foundry and Their Remedial Measures with Industri...AVINASH JURIANI
In this current scenario of globalization, foundries play a key role for manufacturing industries as they are the major source of castings. As a key industry a foundry's performance should be effectively high in terms of production with minimum number of rejections. Castings are the major inputs for most industrial products hence foundry industry is most indispensable. Casting is an integrated process considered as an artwork with experienced professionals for high quality yield, even then in highly controlled environment defects are dominant to take place leading to rejections, contrary to rejections a foundry's key attempt is to satisfy the demands neglecting quality levels.
Effect of Sintering Temperature on Mechanical Properties of Aluminum Compositesijtsrd
Using Al, Al2O3 and SiC, different types of composites have been prepared in this experiment. Green compacts of Al composites were made at a compressing load of 1 ton and 2 ton respectively. These compacts were sintered at two different sintering temperatures of 400 °C and 450 °C in an oxygen free environment using muffle furnace for one hour followed by annealing process which took 12 hours. Sintered compacts were then sintered to micro structural examination and mechanical properties evaluation. Higher hardness has been attained for the composites containing 2.5 SiC. Attempts have been made to describe the influence of sintering temperature on the microstructure and properties of Al Al2O3 SiC composites. Samples are prepared of 100 Al, 97.5 Al 2.5 Al2O3, 92.5 Al 7.5 Al2O3, 95 Al 2.5 Al2O3 – 2.5 SiC, 92.5 Al 5 Al2O3 – 2.5 SiC, 95 Al – 5 Al2O3. The main objective of this experiment is to determine the factors that can increase hardness of Al composites. Mohd Quasim Khan ""Effect of Sintering Temperature on Mechanical Properties of Aluminum Composites"" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-4 , June 2019, URL: https://www.ijtsrd.com/papers/ijtsrd25073.pdf
Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/25073/effect-of-sintering-temperature-on-mechanical-properties-of-aluminum-composites/mohd-quasim-khan
Study of sliding wear rate of hot rolled steel specimen subjected to Zirconia...IJERA Editor
Wear is nothing but loss of material by usage. In a mechanical industry mechanical components will operate
under severe load, temperature and high speeds. Under such a type of situation, when metal to metal contact take
place the surfaces that comes in contact is subjected to wear. These should be considered as a serious affair in an
industry because if the process of wear continues it can reduce service life of the component and also to the
entire mechanical system to which the component has been used. In the light of the above the present work
mainly deals with the study of wear behavior of hot rolled steel with and without zirconia coating on the contact
surface and the effect of zirconia coating with varying thickness.
Surface Processing Operation includes material surface cleaning and surface treating processes which is physically and/or chemically to alter surface texture, Mechanical properties, Physical properties, Chemical Properties etc, to have a better material.
Sensitization of Gold Dust in 430 Grade Stainless SteelIJAEMSJORNAL
'Gold dusting' is a surface defect that is sometimes observed on cold-rolled AISI type 430 stainless steel. Gold dusting is characterized by a sparkling appearance, which results from small flakes of metal on the cold rolled surface, the flakes are mostly elongated in the rolling direction. The processing steps include continuous casting, hot rolling, continuous annealing, and pickling. One possibility is that the flakes of metal are grains that had been undercut by intergranular corrosion such intergranular corrosion may occur during pickling after the annealing step (which itself follows hot rolling). If intergranular corrosion does occur during this pickling step, the intergranular cavities would be elongated by subsequent cold rolling; this can account for the observed morphology of gold dusting. If the steel has been sensitized, intergranular corrosion may occur during pickling. Pickling is commonly carried out by electrolytic descaling in a neutral sodium sulphate solution followed by immersion in a nitric acid/hydrofluoric acid bath. The sensitized type 430 stainless steel does, indeed, suffer intergranular corrosion in a nitric acid/hydrofluoric acid bath, while it is largely unaffected during electrolytic pickling. Hence, sensitization is a possible cause of gold dusting.
IMPROVING OPTIMIZED THE SURFACE QUALITY OF STAINLESS STEEL JIS 440 ON LAPPING...IAEME Publication
This objective of research was studied to study lapping process for achieving high quality alumina the surface quality of stainless steel JIS 440 on lapping process. Factorial experiment was applied to analyze the four-alumina powder size of 0.3 µm and nine-lapping time of 30, 60, 90, 120, 150, 180, 210, 240 and 270 min, respectively. In preparing of specimen surface roughness for experimental, was used the ratio between the alumina powder of 200 g, alumina powder lubricant of 150 ml and water of 1 l which has Five surface roughness values, Ra were then prepared: 0.4 μm, 0.8 μm, 1.2 μm, 1.6 μm and 2.0 μm, respectively. Alumina abrasive powder size of 0.3 µm at a surface roughness of Ra 0.8 µm at 30 min resulted in the best average surface roughness (Ra) of 0.0575 µm when considering the satisfaction value. (Desirability: D) with regard to statistical processing, it was found that the value was as high as 99.37% Correlation of surface quality with lapping parameters was established to achieve process optimization.
Effect of silicon carbide percentage on fracture toughness of aluminium silio...eSAT Journals
Abstract Metal matrix composites are composites in which one component will be a metal and other metal or non metal. It has wide applications in various fields like automobile, turbines blades etc which needs good mechanical properties. This thesis work studies about Aluminium Silicon Carbide metal matrix composites and their properties. Earlier studies revealed that as the percentage of Silicon Carbide is increased the properties get increased up to a limit and fracture toughness gets reduced beyond that. Here, in this work different percentage of SiC is added and fracture toughness is analyzed in terms of Stress intensity factor since fracture toughness cannot be calculated directly. Both software simulation and experimental methods has been done to find out the best percentage composition. Keywords: Metal matrix composites, Aluminium Silicon Carbide, Fracture Toughness, Stress Intensity Factor
Diamond turning is an ultraprecision machining technology for the generation of complex functional surfaces and extremely fine microstructures with the use of geometrically defined diamond cutters.
The cutters can be natural diamond or synthetic diamond depending finishing scale of machining and finishing requirements.
Diamond turn machining is a well-established and affordable process for the fabrication of highly accurate optical components as well as mechanical components requiring micro inch dimensional tolerances.
Diamond turning is used primarily to manufacture ultra precision parts for advanced applications, those that call for extremely high levels of form accuracy and surface finishing.
Casting Defects Analysis in Foundry and Their Remedial Measures with Industri...AVINASH JURIANI
In this current scenario of globalization, foundries play a key role for manufacturing industries as they are the major source of castings. As a key industry a foundry's performance should be effectively high in terms of production with minimum number of rejections. Castings are the major inputs for most industrial products hence foundry industry is most indispensable. Casting is an integrated process considered as an artwork with experienced professionals for high quality yield, even then in highly controlled environment defects are dominant to take place leading to rejections, contrary to rejections a foundry's key attempt is to satisfy the demands neglecting quality levels.
Effect of Sintering Temperature on Mechanical Properties of Aluminum Compositesijtsrd
Using Al, Al2O3 and SiC, different types of composites have been prepared in this experiment. Green compacts of Al composites were made at a compressing load of 1 ton and 2 ton respectively. These compacts were sintered at two different sintering temperatures of 400 °C and 450 °C in an oxygen free environment using muffle furnace for one hour followed by annealing process which took 12 hours. Sintered compacts were then sintered to micro structural examination and mechanical properties evaluation. Higher hardness has been attained for the composites containing 2.5 SiC. Attempts have been made to describe the influence of sintering temperature on the microstructure and properties of Al Al2O3 SiC composites. Samples are prepared of 100 Al, 97.5 Al 2.5 Al2O3, 92.5 Al 7.5 Al2O3, 95 Al 2.5 Al2O3 – 2.5 SiC, 92.5 Al 5 Al2O3 – 2.5 SiC, 95 Al – 5 Al2O3. The main objective of this experiment is to determine the factors that can increase hardness of Al composites. Mohd Quasim Khan ""Effect of Sintering Temperature on Mechanical Properties of Aluminum Composites"" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-4 , June 2019, URL: https://www.ijtsrd.com/papers/ijtsrd25073.pdf
Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/25073/effect-of-sintering-temperature-on-mechanical-properties-of-aluminum-composites/mohd-quasim-khan
Study of sliding wear rate of hot rolled steel specimen subjected to Zirconia...IJERA Editor
Wear is nothing but loss of material by usage. In a mechanical industry mechanical components will operate
under severe load, temperature and high speeds. Under such a type of situation, when metal to metal contact take
place the surfaces that comes in contact is subjected to wear. These should be considered as a serious affair in an
industry because if the process of wear continues it can reduce service life of the component and also to the
entire mechanical system to which the component has been used. In the light of the above the present work
mainly deals with the study of wear behavior of hot rolled steel with and without zirconia coating on the contact
surface and the effect of zirconia coating with varying thickness.
Surface Processing Operation includes material surface cleaning and surface treating processes which is physically and/or chemically to alter surface texture, Mechanical properties, Physical properties, Chemical Properties etc, to have a better material.
Sensitization of Gold Dust in 430 Grade Stainless SteelIJAEMSJORNAL
'Gold dusting' is a surface defect that is sometimes observed on cold-rolled AISI type 430 stainless steel. Gold dusting is characterized by a sparkling appearance, which results from small flakes of metal on the cold rolled surface, the flakes are mostly elongated in the rolling direction. The processing steps include continuous casting, hot rolling, continuous annealing, and pickling. One possibility is that the flakes of metal are grains that had been undercut by intergranular corrosion such intergranular corrosion may occur during pickling after the annealing step (which itself follows hot rolling). If intergranular corrosion does occur during this pickling step, the intergranular cavities would be elongated by subsequent cold rolling; this can account for the observed morphology of gold dusting. If the steel has been sensitized, intergranular corrosion may occur during pickling. Pickling is commonly carried out by electrolytic descaling in a neutral sodium sulphate solution followed by immersion in a nitric acid/hydrofluoric acid bath. The sensitized type 430 stainless steel does, indeed, suffer intergranular corrosion in a nitric acid/hydrofluoric acid bath, while it is largely unaffected during electrolytic pickling. Hence, sensitization is a possible cause of gold dusting.
Turbo-Abrasive Machining in the Continuous Flow Environment Dr Michael Massarsky. Turbo-Finish Corporation, 917 518 8205 michael@turbofinish.com
turbofinish.wordpress.com
International Journal of Engineering Research and Development (IJERD)IJERD Editor
journal publishing, how to publish research paper, Call For research paper, international journal, publishing a paper, IJERD, journal of science and technology, how to get a research paper published, publishing a paper, publishing of journal, publishing of research paper, reserach and review articles, IJERD Journal, How to publish your research paper, publish research paper, open access engineering journal, Engineering journal, Mathemetics journal, Physics journal, Chemistry journal, Computer Engineering, Computer Science journal, how to submit your paper, peer reviw journal, indexed journal, reserach and review articles, engineering journal, www.ijerd.com, research journals,
yahoo journals, bing journals, International Journal of Engineering Research and Development, google journals, hard copy of journal
Technical article reprint on the high-speed and high-intensity and high-quality Centrifugal iso-Finishing method.. The methods used widely on aerospace, motorsports, automotive, medical, dental, orthodontic and jewelry manufactured parts. For additional information contact Dave Davidson at ddavidson@deburring-tech-group.com. Ask about the free sample part finishing program.
See also the technical blog at https://dryfinish.wordpress.com
Centrifugal Iso-Finishing Technical article as seen in Products Finishing mag...Dave Davidson
This high-speed, high-intensity mass finishing
method can improve part performance. Centrifugal iso-finishing can be used not only for deburring and edge-contour, but also to
develop surface finish attributes that improve the performance,
surface integrity and service life of components.
A High-Speed, High-Energy Alternative
Centrifugal iso-finishing is a high-speed and high-intensity
mass finishing method in which abrasive or polishing materials are caused to interact with part edges and surfaces
with 10 times the surface pressure of low-energy finishing
methods. What this means, in practical terms, is that it is
possible to produce very refined surface finishes in abbreviated process cycle times. It also means that parts with
complex and detailed geometries can be deburred with a
minimum of manual intervention.
Technical article on Centrifugal Iso-Finishing for deburring and polishing.
Contact:
Dave Davidson
Deburring/Finishing Technologist
SME Tech Community Advisor
dryfinish@gmail.com | 509.230.6821
http://dryfinish.wordpress.com
http://about.me/dave.davidson
http://partsfinished.wordpress.com
Finished part portfolio: https://www.flickr.com/photos/72325472@N04/albums/72157686262863672
________________________
Free Sample Processing
Contract Deburring and Finishing Services
High Energy Finishing Equipment and Process Development
This presentation contain discription about Fine finishing process of complex shape material which cannot be finished by normal processess. three type of finishing process has been described they are Abrasive flow machining, MAgnetic Abrasive Finishing, Magneto Rheological abrasive finishing.
Machining of Sic - Metal Matrix Composite (MMC) by Polycrystalline Diamond (P...ijsrd.com
In this paper, wear of polycrystalline diamond (PCD) cutting tools and the surface integrity during machining of SiC – Metal Matrix Composite (MMC) is discussed. An attempt is made to establish relation between the hardness of the tool and the flank wear. A newly developed PCD tool, which is superior in hardness with lower flank wear than the conventional tools is introduced. During machining with PCD tools, the severity of transfer material on the tools increased significantly with cutting distance and cutting speed. The superior surface finish obtained with the PCD tools cannot be merely explained by their low wear. The low degree of adhesion that these tools had with the work material appeared to be the main reason for the superior surface obtained at both low and high cutting speeds. At low cutting speed, when the use of coolant resulted in a marked reduction in the amount of work material on the machined work pieces, high Ra and P-V values can be obtained.
Immunizing Image Classifiers Against Localized Adversary Attacksgerogepatton
This paper addresses the vulnerability of deep learning models, particularly convolutional neural networks
(CNN)s, to adversarial attacks and presents a proactive training technique designed to counter them. We
introduce a novel volumization algorithm, which transforms 2D images into 3D volumetric representations.
When combined with 3D convolution and deep curriculum learning optimization (CLO), itsignificantly improves
the immunity of models against localized universal attacks by up to 40%. We evaluate our proposed approach
using contemporary CNN architectures and the modified Canadian Institute for Advanced Research (CIFAR-10
and CIFAR-100) and ImageNet Large Scale Visual Recognition Challenge (ILSVRC12) datasets, showcasing
accuracy improvements over previous techniques. The results indicate that the combination of the volumetric
input and curriculum learning holds significant promise for mitigating adversarial attacks without necessitating
adversary training.
Sachpazis:Terzaghi Bearing Capacity Estimation in simple terms with Calculati...Dr.Costas Sachpazis
Terzaghi's soil bearing capacity theory, developed by Karl Terzaghi, is a fundamental principle in geotechnical engineering used to determine the bearing capacity of shallow foundations. This theory provides a method to calculate the ultimate bearing capacity of soil, which is the maximum load per unit area that the soil can support without undergoing shear failure. The Calculation HTML Code included.
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
CFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptxR&R Consult
CFD analysis is incredibly effective at solving mysteries and improving the performance of complex systems!
Here's a great example: At a large natural gas-fired power plant, where they use waste heat to generate steam and energy, they were puzzled that their boiler wasn't producing as much steam as expected.
R&R and Tetra Engineering Group Inc. were asked to solve the issue with reduced steam production.
An inspection had shown that a significant amount of hot flue gas was bypassing the boiler tubes, where the heat was supposed to be transferred.
R&R Consult conducted a CFD analysis, which revealed that 6.3% of the flue gas was bypassing the boiler tubes without transferring heat. The analysis also showed that the flue gas was instead being directed along the sides of the boiler and between the modules that were supposed to capture the heat. This was the cause of the reduced performance.
Based on our results, Tetra Engineering installed covering plates to reduce the bypass flow. This improved the boiler's performance and increased electricity production.
It is always satisfying when we can help solve complex challenges like this. Do your systems also need a check-up or optimization? Give us a call!
Work done in cooperation with James Malloy and David Moelling from Tetra Engineering.
More examples of our work https://www.r-r-consult.dk/en/cases-en/
Water scarcity is the lack of fresh water resources to meet the standard water demand. There are two type of water scarcity. One is physical. The other is economic water scarcity.
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Experimental Study on Surface Roughness by Using Abrasive Particles
1. A.K.Chaitanya.et al. Int. Journal of Engineering Research and Application www.ijera.com
ISSN : 2248-9622, Vol. 7, Issue 5, ( Part -4) May 2017, pp.34-39
www.ijera.com DOI: 10.9790/9622-0705043439 34 | P a g e
Experimental Study on Surface Roughness by Using Abrasive
Particles
A.K.Chaitanya1
, D.Kishore Babu2
, K.V.N.Girish Kumar3
, K.Prakash4
.
1
Assistant Professor, Department Of Mechanical Engineering, PSCMR College of Engineering & Technology,
VJA.
2
Assistant Professor, Department Of Mechanical Engineering, PSCMR College of Engineering & Technology,
VJA.
3
Assistant Professor, Department Of Mechanical Engineering, PSCMR College of Engineering & Technology,
VJA.
4
Assistant Professor, Department Of Mechanical Engineering, PSCMR College Of Engineering & Technology,
VJA.
ABSTRACT
New advancement of technology and never satisfying demands of the civilization are putting huge pressure on
the natural fuel resources and these resources are at a constant threat to its sustainability. Surface finish has a
vital influence on functional properties such as wear resistance and power loss due to friction on most of the
engineering components. Voltage, mesh number, revolutions per minute (rpm) of electromagnet, and percentage
weight of abrasives has been identified as important process parameters affecting surface roughness. The
experiments were planned using response surface methodology and percentage change in surface roughness
(ΔRa) was considered as response. Analysis of experimental data showed that percentage change in surface
roughness (ΔRa) was highly influenced by mesh number followed by percentage weight of abrasives, rpm of
electromagnet, and voltage. The process has been investigated extensively in the finishing of cylindrical
surfaces. The surface finish was found to improve significantly with an increase in the grain size, relative size of
abrasive particles vis-à-vis the iron particles, feed rate and current. Super finishing is a micro-finishing process
that produces a controlled and smooth surface condition on work pieces. It is not primarily a sizing operation, its
major purpose is to produce a surface on a work piece capable of sustaining uneven distribution of a load by
improving the geometrical accuracy. The wear life of the parts micro finished to maximum smoothness is
extended considerably. According to the design of experimentation, mathematical model for Lapping operation
on advance ceramic material is proposed. In order to get minimum values of the surface roughness, optimization
of the mathematical model is done and optimal operation of the examined factors is going to be determined. The
obtained results will be, according to the experiment plan, valid for the testing of ceramic material by Lapping
operation.
I. INTRODUCTION
1.1 SURFACE FINISHING
Surface finishing is a broad range of industrial
processes that alter the surface of a manufactured
item to achieve a certain property. Finishing
processes may be employed to: improve appearance,
adhesion or wet ability, solder ability, corrosion
resistance, tarnish resistance, chemical resistance,
wear resistance, hardness, modify electrical
conductivity, remove burrs and other surface flaws,
and control the surface friction. In limited cases
some of these techniques can be used to restore
original dimensions to salvage or repair an item. An
unfinished surface is often called mill finish. Surface
finishing processes can be categorized by how they
affect the work piece:
Removing or reshaping finishing
Adding or altering finishing
Mechanical processes may also be categorized
together because of similarities the final surface
finish.
POLISHING:
Polishing and buffing are finishing processes for
smoothing a work piece’s surface using an abrasive
and a work wheel or a leather strop. Technically
polishing refers to processes that use an abrasive
that is glued to the work wheel, while buffing uses a
loose abrasive applied to the work wheel. Polishing
is a more aggressive process while buffing is less
harsh, which leads to a smoother, brighter finish. A
common misconception is that a polished surface
has a mirror bright finish, however most mirror
bright finishes are actually buffed. Polishing is often
used to enhance the appearance of an item, prevent
contamination of instruments, remove oxidation,
RESEARCH ARTICLE OPEN ACCESS
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create a reflective surface, or prevent corrosion in
pipes. In metallographic and metallurgy, polishing is
used to create a flat, defect-free surface for
examination of a metal's microstructure under a
microscope. Silicon-based polishing pads or a
diamond solution can be used in the polishing
process. Polishing stainless steel can also increase
the sanitary benefits of stainless steel.The removal
of oxidization (tarnish) from metal objects are
accomplished using a metal polish or tarnish
remover; this is also called polishing. To prevent
further unwanted oxidization, polished metal
surfaces may be coated with wax, oil, or lacquer.
This is of particular concern for copper alloy
products such as brass and bronze.
Mechanical properties: The strength of polished
products is normally higher than their rougher
counterpart owing to the removal of stress
concentrations present in the rough surface. They
take the form of corners and other defects, which
magnify the local stress beyond the inherent strength
of the material. Polishing with very fine abrasive
differs physically from coarser abrasion, in that
material is removed on a molecular level, so that the
rate is correlated to the boiling point rather than to
the melting point of the material being polished.
1.2 SELECTION OF ABRASIVES Common
Abrasive Materials
Synthetic Diamond
Cubic Boron Nitride (CBN)
Aluminium Oxide
Silicon Carbide (Sic)
Aluminium Oxide:
Aluminium oxide is used for its hardness
and strength. It is widely used as an abrasive,
including as a much less expensive substitute for
industrial diamond. Many types of sandpaper use
aluminium oxide crystals. In addition, its low heat
retention and low specific heat make it widely used
in grinding operations, particularly cut-off tools. As
the powdery
Fig1: Aluminium Oxide Grit
Abrasive mineral aloxite, it is a major
component, along with silica, of the cue tip "chalk"
used in billiards. Aluminium oxide powder is used
in some CD/DVD polishing and scratch-repair kits.
Its polishing qualities are also behind its use in
toothpaste. Aluminum oxide can be grown as a
coating on aluminum by anodizing or by plasma
electrolytic oxidation (see the "Properties" above).
Both the hardness and abrasion-resistant
characteristics of the coating originate from the high
strength of aluminum oxide, yet the porous coating
layer produced with conventional direct current
anodizing procedures is within a 60-70 Rockwell
hardness C range which is comparable only to
hardened carbon steel alloys, but considerably
inferior to the hardness of natural and synthetic
corundum. Instead, with plasma electrolytic
oxidation, the coating is porous only on the surface
oxide layer while the lower oxide layers are much
more compact than with standard DC anodizing
procedures and present a higher crystalline due to
the oxide layers being re melted and densified to
obtain α-Al2O3 clusters with much higher coating
hardness values circa 2000 Vickers hardness.
Alumina is used to manufacture tiles, which are
attached inside pulverized fuel lines, and flue gas
ducting on coal fired power stations to protect high
wear areas. They are not suitable for areas with high
impact forces as these tiles are brittle and
susceptible to breakage.
1.3 NEED FOR SUFACE FINISHING: Surface
finish, or texture, can be viewed from two very
different perspectives. From the machinist's point of
view, texture is a result of the manufacturing
process. By altering the process, the texture can be
changed. From the part designer's point of view,
surface finish is a condition that affects the
functionality of the part to which it applies. By
changing the surface finish specification, the part's
functionality can be altered—and hopefully,
improved. Bridging the gap between these two
perspectives is the manufacturing engineer, who
must determine how the machinist is to produce the
surface finish specified by the design engineer. The
methods one chooses to measure surface finish,
therefore, depend upon perspective, and upon what
one hopes to achieve.
1.4 SCOPE OF SURFACE FINISHING:
Optimize conventional wet processes to
achieve near zero discharge and risk --
Improve the efficiency and performance of
conventional surface finishing processes to
reduce chemical usage, worker exposure risk
and waste generation, while maintaining or
improving surface finish quality, processing
speed and capacity.
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Improve process monitoring and control
systems – Automate surface finishing process
lines. For manual process lines, deploy state-of-
the-art software to enhance information access
and process verification.
Pursue sustainable manufacturing – Use
processes and systems that are non-polluting,
energy conserving, natural resource conserving,
economically efficient, and safe for workers, the
community, and consumers.
Improve energy efficiency -- Use more energy
efficient equipment and/or modify
manufacturing processes to increase efficiency
and reduce energy consumption.
Developing and Implementing New
Technology:
Change to “greener” process chemistries –
Change to alternative “green” chemistries that
can meet surface finishing process requirements
while reducing or eliminating the use and
generation of hazardous substances.
Change from “wet” processes to “dry”
processes -- Change from conventional surface
finishing immersion chemistry solutions to
alternative metal deposition technologies (e.g.
HVOF or PVD)
Change substrate materials from finished
metals to non-metals -- Change materials and
manufacturing processes from metal finishing
to non-metals, such as composites or plastics.
Develop new metal alloys that reduce surface
finishing requirements -- Use new metal
alloys that provide sufficient corrosion
resistance and reduce or eliminate the need for
metal finishing using toxic chemical processes
(e.g. new stainless steel alloy that can replace
steel coated with cadmium).
Develop nanotechnology -- Use Nano
crystalline metal coating processes or using
nano material-enhanced metal or non-metal
substrates.
II. METHODOLOGY
2.1 Abrasive Finishing Of Rough Surfaces
Surface finishing can be done with the help
of Aluminum oxide abrasives. The abrasives are
rotated in the tub. The abrasives are whirled in tub.
The resonation is very rapid and the abrasives strike
one another causing friction. The work piece dipped
in to these abrasives. These abrasives will strike the
coarse structure and the excess material is removed
from the surface of the work piece. Hence, burrs
formed are deposited in the abrasives.
Fig 2
2.2 ALUMINUM OXIDE ABRASIVES
Aluminum oxide is used for its hardness
and strength. It is widely used as an abrasive,
including as a much less expensive substitute for
industrial diamond. Many types of sandpaper use
aluminum oxide crystals. In addition, its low heat
retention and low specific heat make it widely used
in grinding operations, particularly cutoff tools. As
the powdery abrasive mineral aloxite, it is a major
component, along with silica, of the cue tip“chalk”
used in billiards. Aluminum oxide powder is used in
some CD/DVD polishing and scratch-repair kits. Its
polishing qualities are also behind its use in
toothpaste.
2.3 WORK PIECE MATERIALS: STAINLESS
STEEL:
In metallurgy, stainless steel, also known
as inox steel or inox from French inoxydable (in
oxidizable), is a steel alloy with a minimum of
10.5%[1]
chromium content by mass. Stainless steel is
notable for its corrosion resistance, and it is widely
used for food handling and cutlery among many
other applications.
Stainless steel does not readily corrode, rust
or stain with water as ordinary steel does. However,
it is not fully stain-proof in low-oxygen, high-
salinity, or poor air-circulation environments.[2]
There are various grades and surface finishes of
stainless steel to suit the environment the alloy must
endure. Stainless steel is used where both the
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properties of steel and corrosion resistance are
required.
BRASS: Brass is a metal alloy made of copper and
zinc; the proportions of zinc and copper can be
varied to create a range of brasses with varying
properties. It is a substitution alloy: atoms of the two
constituents may replace each other within the same
crystal structure.
IRON AND ITS OXIDES:
Iron chemical compounds have many uses. Iron
oxide mixed with aluminum powder can be ignited
to create a termite reaction, used in welding and
purifying ores. Iron forms binary compounds with
the halogens and the chalcogens. Among its organo
metallic compounds is ferrocene, the first sandwich
compound discovered.
2.4 Surface Finish Measurement:
Surface finish measurement, sometimes
called surface texture measurement, is the
characterizing of a surface’s quality or conformance
to expectations (for example, to an engineering
specification) through measurement of its variations
in local height over a given distance. There are
several aspects of the surface to be consideredered.
Fig3Ground Surface Finish Measurement Surface
Roughness vs. Surface Finish:
Surface roughness measurement is a
quantitative assessment of very closely occurring
surface irregularities, and is sometimes used
interchangeably with the term surface finish
measurement. There is a difference in context,
however: while surface roughness is a general term
about the amount of surface variation (at a very
small scale) on any given surface, whether natural,
man-made or found, “surface finish” is a term
implying a surface that has been deliberately
modified or engineered, with an end in mind.
2.5 OPERATING PARAMETERS:
Parameters are the quantitative methods
used to describe and compare surface characteristics.
These are defined by the algorithms that are used to
turn raw measurement data into a numerical value.
Although more than 100 parameters exist,
machinists have traditionally relied upon just one or
two parameters. Currently, Ra, or average
roughness, is the parameter most widely specified
and measured. The algorithm for Ra calculates the
average height of the entire surface, within the
sampling length, from the mean line. It serves as an
effective means of monitoring process stability,
which explains why it is the predominant parameter
in use today.
THEORETICAL CALCULATIONS
AND EXPERIMENTAL ANALYSIS
3.1THEORITICAL CALCULATIONS;
Equivalent Ra values for Surface Finish Grade
Numbers:
Older drawings may use roughness grade
numbers to indicate Ra values. The following table
is given in ISO 1302:1992.
L = evaluation length
Z(x) = the profile height function
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3.2 Experimental analysis:
Fig-4 fabricated machine
3.3 OPTICAL PROFILOMETER
Fig-5 optical profilometer
3.4UNPOLISHED BOLTS AND NUTS
Fig-6 unpolished bolts and nuts
3.5 POLISHED NUTS AND BOLTS:
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III. RESULTS AND DISCUSSIONS
Surface texture of a part or a product has
significant effects on its functionality, physical-
mechanical properties and visual appearance. In
particular for miniature products, the implication of
surface quality becomes critical owing to the
presence of geometrical features with micro/nano-
scale dimensions. Qualitative and quantitative
assessments of surface texture are carried out
predominantly by profile parameters, which are
often insufficient to address the contribution of
constituent spatial components with varied
amplitudes and wavelengths. In this context, this
article presents a novel approach for advanced
measurement and analysis of profile average
roughness (Ra) and its spatial distribution at different
wavelength intervals. The applicability of the
proposed approach was verified for three different
surface topographies prepared by grinding, laser
micro-polishing and micro-milling processes. From
the measurement and analysis results, Ra(λ) spatial
distribution was found to be an effective measure of
revealing the contributions of various spatial
components within specific wavelength intervals
towards formation of the entire surface profile. In
addition, the approach was extended to the
measurement and analysis of areal average
roughness Sa(λ) spatial distribution within different
wavelength intervals. Besides, the proposed method
was demonstrated to be a useful technique in
developing a functional correlation between a
manufacturing process and its corresponding surface
profile.
REFERENCES
[1] Boothroyd, G. and Knight, W. A., (1989),
Fundamentals of Machining and Machine
Tools, Second Edition, Marcel Dekker
Inc., New York.
[2] Charisis, D., Koutayas, S.O., Kamposiora,
P., Doukoudakis, A. Spectrometric
evaluation of the influence of different
backgrounds on the colour of glass-
infiltrated ceramic veneers. Eur J Esthet
Dent. 2006;1:142–156.
[3] Brosheer, B. C., (1948), “How Smooth is
Smooth? Part-I, Specification and
Evaluation of Machined Finishes”,
American Machinist, McGrow-Hill
Publishing Company, pp. 97-112.
[4] CIE 1971: International Commission on
Illumination. Colorimeter: Illumination.
Publication CIE No. 15 (E-1.3.1), .