A detailed study on grinding of metal matrix composites with resin bonded and plated diamond wheels have been carried out to evaluate the surface quality. The measurands namely grinding force and temperature during grinding were monitored online. Surface finish was measured offline using a stylus based instrument and the ground surface was observed through Scanning Electron Microscope (SEM) for process status evaluation. From the study, it was found that better surface quality (based on surface finish and SEM of machined surface) was achievable with resin bonded wheel as compared to...
Computer vision with digital image processing is one of the widely used research tools and finds many applications in various branches of engineering. In a manufacturing environment, it is used for many applications such as inspection, recognition and navigation. In this work, the objective is to evaluate the surface roughness of uniformly moving machined surface using machine vision technique. Basically, the problem in estimating the roughness of moving surfaces based on their images is blurring. It is important that blurred image has to be corrected for its distortion and restored before...
The present day manufacturing environment requires accurate inspection of both dimension and form while minimizing the cost and time of inspection. Flatness error is an important form tolerance that is used for the control of machined surfaces. The evaluation of flatness error depends on a variety of factors such as selection of sampling plan - sample size and sample point locations, the method of evaluating the form error and the nature of the manufactured surfaces amongst which the sample size is very critical. In most cases the sample size is decided based on the experience of the...
Electroless nickel (EN) coatings have gained widespread acceptance as it provides uniform deposit on irregular surfaces, direct deposition on surface activated non – conductors, high hardness and excellent resistance to wear, abrasion and corrosion. The effect of surfactants on the surface roughness of electroless Nickel – Phosphorus surface protective coating obtained from an alkaline bath is presented in this paper. In this study the influence of surfactants sodium dodecylsulfate (SDS) and cetyl trimethyl ammonium bromide (CTAB) on the surface roughness of coated samples were investigated....
Non-contact techniques for rapid and accurate mapping of micro-machined surfaces are important for the optoelectronic industry. Interferometry is an important tool for precision metrology of surfaces. It has been used for applications such as surface profiling, roughness measurement and quality testing of optical elements. The singlewavelength conventional interferometry can handle the smoothly varying surface profiles and step-heights less than half a wavelength. In this paper we describe a two wavelength microscopic TV interferometric system which removes ambiguity associated with the...
A fuzzy modeling approach is presented in this paper for the prediction of surface roughness (Ra) in face milling of Metal Matrix Composites (MMC). This study deals with the experimental results obtained during face milling of MMC Al/SiC, 15% volume fraction by using face milling cutter with K10 grade insert. The data used for the training and checking of the model performance were obtained from experiments conducted on a vertical milling machine. The model uses the cutting speed, depth of cut and the feed as input data and the surface roughness as the output data. The process of model...
Three dimensional measurements (3D) of surface topography are increasingly being recognized as the most adequate method for obtaining a better understanding of surfaces. The dimensional and surface metrology department at the National Institute for Standards in Egypt (NIS) developed a computer-controlled system for 3D surface measurements. The developed system is based on a 2D surface measuring instrument using a stylus contact method. A positioning table is used to displace the specimen underneath the stylus in a cross direction to the traverse stroke. The system can scan small areas on the...
Three Dimensional Printing (3DP) is one among the Rapid Prototyping (RP) techniques that is evolving towards Rapid Manufacturing (RM). Speed and accuracy are the functional requirements of an RP system. The prototype quality is evaluated by surface finish, dimensional and form accuracy obtained from RP process. There is lack of published data dealing with influence of process parameters on prototype quality in 3DP process. The experiment design was made using Taguchi orthogonal array and a evaluation model was built for each experimental run. Using a 3-D coordinate measuring machine and...
Modeling and prediction of surface finish of work pieces in machining can play an important role in the automation of manufacturing operations. As surface generation in machining is a complex process, the exact variables and parameters that have to be used for surface roughness prediction models are still under dispute. This work attempts to evaluate and predict surface roughness during turning operation using artificial neural network and multiple regression analysis. In addition to the conventional cutting conditions like cutting speed, feed and depth of cut, this work also used cutting...
The influence of the lighting conditions on the grey level distribution and thereby on the estimation of the surface roughness using machine vision system is reported in this work. The light to specimen distance, the grazing angle and the inclination of the striations are varied and their effect on the image parameter, the arithmetic average of the grey level is studied. Mild steel, brass and aluminium specimens are machined for different roughness for the study. Trials were made using the design of experiments procedure and the influence of the different factors are studied. Taguchi’s...