Surface roughness refers to the irregularities or deviations in the texture of a material's surface. It is a measure of the fine-scale variations in height on the surface, which can range from microscopic to visible to the naked eye. Surface roughness is typically measured in terms of the average roughness, which is the arithmetic mean of the vertical deviations from the ideal surface. The measurement of surface roughness is done using specialized instruments called profilometers, which use a stylus or a laser to scan the surface and record the height variations. The data obtained from the profilometer is then used to calculate various parameters that quantify the surface roughness.
There are several methods used to measure surface roughness. One common method is the stylus profilometry, where a stylus is dragged across the surface and the vertical movements are recorded. Another method is optical profilometry, which uses a laser or white light interferometry to measure the surface height variations. Additionally, atomic force microscopy (AFM) can be used to measure surface roughness at the nanoscale by scanning a sharp tip over the surface. Each method has its advantages and limitations, and the choice of method depends on factors such as the material being measured, the required resolution, and the desired measurement speed.
AddUp, a joint venture created by Michelin and Fives, is a global metal additive manufacturing OEM and service provider of powder bed fusion (PBF) and directed energy deposition (DED) technologies. They have launched a suite of new process monitoring software to bolster the capabilities of the FormUp 350 PBF machine: AddUp Dashboards, Recoat Monitoring, and Meltpool Monitoring. This new software suite for its metal 3D printing technology optimizes part quality for prototyping and end-use industrial applications.
Posted by on 2022-07-06
Nidec Machine Tool Corporation recently developed the "SE25FR Plus," a gear shaping machine dedicated to making high-precision small-module gears used in robots. The company simultaneously developed a small-module cutting tool specifically for the new gear shaping machine. By providing this dual support in high-precision gear cutting machines and cutting tools from a single source, Nidec Machine Tool responds to the need for reduction gears of increasingly higher precision in the expanding global robot market.
Posted by on 2022-06-30
Klingelnberg examines gear noise behavior and the evolution of the electric powertrain.
Posted by on 2022-06-14
In July, Raymond J. Drago, P.E.—chief engineer of Drive Systems Technology, Inc. (DST), a mechanical power transmission consulting organization that he founded in 1976—will lead an IACET-accredited course on both the geometry and rating of involute splines of various types along with their applications. Topics under discussion include spline configuration variations, including half depth, full depth, and special function designs; both fixed and flexible spline configurations in terms of usage and design; lubrication methods, including grease, oil bath, and flowing oil, as well as coatings appropriate for various spline applications; and shear and compressive stress rating methods with analyses methodology in both equation and graphical methodology via various rating charts.
Posted by on 2022-05-29
Surface roughness can have a significant impact on the performance of a product or material. In many applications, such as sealing, friction, and adhesion, a smooth surface is desirable to ensure proper functioning. Surface roughness can affect the contact area, frictional forces, wear resistance, and even the appearance of a product. For example, in automotive engines, a high surface roughness can lead to increased friction and energy losses, reducing fuel efficiency. In contrast, in certain applications like coatings or adhesives, a controlled roughness can enhance bonding and improve performance.
The industry standards for surface roughness measurement vary depending on the specific industry and application. For example, in the manufacturing industry, the most commonly used standard is the ISO 4287, which provides guidelines for the measurement and characterization of surface texture. Other standards, such as the ASME B46.1 and the ANSI/ASME B46.1M, provide guidelines for specific industries like aerospace and automotive. These standards define parameters, measurement techniques, and tolerances for surface roughness, ensuring consistency and quality in manufacturing processes.
Yes, surface roughness can be controlled or modified during the manufacturing process. Various techniques can be employed to achieve the desired surface roughness, depending on the material and application. For example, machining processes like grinding, milling, or lapping can be used to remove material and reduce roughness. Surface treatments such as polishing, sandblasting, or chemical etching can also be applied to modify the surface texture. Additionally, the choice of cutting tools, machining parameters, and material selection can influence the resulting surface roughness.
There are several common causes of surface roughness in manufacturing. One major cause is the inherent nature of the material itself, such as the presence of impurities, grain boundaries, or surface defects. Another cause is the manufacturing process, including factors like tool wear, improper machining parameters, or inadequate cooling and lubrication. Environmental factors, such as temperature and humidity, can also affect surface roughness. Additionally, handling and storage practices can introduce surface damage or contamination, leading to increased roughness.
Surface roughness can be reduced or improved for better product quality through various methods. One approach is to optimize the machining process by selecting appropriate cutting tools, controlling machining parameters, and ensuring proper cooling and lubrication. Surface treatments like polishing, buffing, or chemical etching can be used to smoothen the surface and reduce roughness. Additionally, post-processing techniques like honing or grinding can be employed to achieve the desired surface finish. It is important to note that the specific method chosen to reduce surface roughness will depend on the material, application, and desired level of roughness.
When inspecting gearbox internals, various techniques are employed to ensure a thorough examination. One commonly used method is visual inspection, where technicians visually examine the gearbox components for any signs of wear, damage, or misalignment. This may involve using specialized tools such as borescopes or endoscopes to access hard-to-reach areas. Another technique is non-destructive testing, which includes methods like ultrasonic testing, magnetic particle inspection, and dye penetrant inspection. These techniques help identify any internal defects or cracks that may not be visible to the naked eye. Additionally, vibration analysis is often employed to detect any abnormal vibrations or noises that could indicate internal issues. By combining these techniques, gearbox internals can be thoroughly inspected to ensure optimal performance and reliability.
When selecting corrosion-resistant screw materials, several factors are taken into consideration. The type of environment the screw will be exposed to is a crucial factor. For instance, screws used in marine environments require materials that can withstand saltwater corrosion. The type of metal used in the screw is also important. Stainless steel is a popular choice for corrosion-resistant screws due to its high resistance to rust and corrosion. The grade of stainless steel used is also a consideration, with higher grades offering better corrosion resistance. The coating on the screw is another factor, with options such as zinc plating, black oxide, and ceramic coatings providing additional protection against corrosion. The size and shape of the screw are also taken into account, as certain shapes and sizes may be more prone to corrosion. Overall, selecting the right corrosion-resistant screw material involves a careful consideration of the specific application and environment in which the screw will be used.
Screw flights in barrel systems are refurbished by first removing the worn or damaged flights from the screw shaft. The next step involves cleaning and inspecting the shaft and remaining flights for any signs of wear or damage. Once the shaft and remaining flights are deemed to be in good condition, new flights are then welded or attached to the shaft using specialized equipment and techniques. The refurbished screw flights are then carefully balanced and tested to ensure proper functionality and performance. This process may also involve the use of abrasives, welding rods, and other materials to ensure a high-quality refurbishment. Additionally, the refurbished screw flights may undergo surface treatments or coatings to enhance their durability and resistance to wear. Overall, the refurbishment of screw flights in barrel systems requires precision, expertise, and attention to detail to ensure optimal performance and longevity.
The primary causes of gear tooth wear in industrial gearboxes can be attributed to several factors, including inadequate lubrication, high operating temperatures, abrasive contaminants, misalignment, and overloading. Inadequate lubrication can lead to increased friction and heat generation, causing accelerated wear on gear teeth. High operating temperatures can also contribute to wear by breaking down the lubricant and reducing its effectiveness. Abrasive contaminants, such as dirt and metal particles, can cause abrasive wear on gear teeth, leading to pitting and surface damage. Misalignment of gears can result in uneven distribution of load and increased contact stress, leading to localized wear on gear teeth. Overloading the gearbox can also lead to excessive stress on the gear teeth, causing accelerated wear and potential failure. Overall, a combination of these factors can contribute to gear tooth wear in industrial gearboxes, necessitating regular maintenance and monitoring to prevent premature failure.
Lubricant additives in gearboxes are assessed for effectiveness through a comprehensive evaluation process that involves various tests and measurements. These assessments aim to determine the ability of the additives to enhance the performance and longevity of the gearbox. One common method is the evaluation of the lubricant's film thickness and its ability to reduce friction and wear. This involves measuring the thickness of the lubricant film under different operating conditions and comparing it to the desired levels. Additionally, the additives' ability to prevent oxidation and corrosion is assessed through tests that simulate harsh operating conditions. Other evaluations include measuring the lubricant's ability to maintain its viscosity and resist shearing forces, as well as its compatibility with different materials commonly found in gearboxes. Overall, these assessments provide valuable insights into the effectiveness of lubricant additives in optimizing gearbox performance and ensuring its smooth operation.
Hard-facing gearbox components typically involve the use of advanced technologies such as thermal spraying, laser cladding, and weld overlay. Thermal spraying is a process that involves the application of a coating material onto the surface of the gearbox components using a high-velocity flame or plasma jet. This technology allows for the deposition of a hard and wear-resistant layer, enhancing the durability and performance of the components. Laser cladding, on the other hand, utilizes a high-energy laser beam to melt and fuse a powdered coating material onto the surface of the components. This technique provides precise control over the coating thickness and composition, resulting in improved wear resistance and reduced friction. Weld overlay involves the deposition of a hard-facing material onto the surface of the components through welding. This method allows for the customization of the coating properties to meet specific requirements, such as hardness, toughness, and corrosion resistance. Overall, these advanced technologies play a crucial role in enhancing the longevity and reliability of gearbox components in various industrial applications.
Lubricant degradation in gearbox systems is typically analyzed through a combination of methods, including oil analysis, viscosity measurements, and wear particle analysis. Oil analysis involves testing the lubricant for various properties such as acidity, base number, and oxidation levels. Viscosity measurements are used to monitor changes in the lubricant's thickness, which can indicate degradation. Wear particle analysis involves examining the lubricant for metal particles and other contaminants that can indicate wear and tear on the gearbox components. Additionally, infrared spectroscopy and elemental analysis can be used to identify specific degradation products and contaminants in the lubricant. These methods provide a comprehensive understanding of the condition of the lubricant in gearbox systems, allowing for proactive maintenance and replacement to prevent equipment failure.
When selecting polymer additives for gearboxes, there are several important considerations to keep in mind. Firstly, the compatibility of the additives with the base polymer is crucial to ensure optimal performance and stability. It is essential to choose additives that have a strong affinity for the polymer matrix and can effectively enhance its mechanical properties. Additionally, the thermal stability of the additives is vital, as gearboxes often operate under high temperatures and require additives that can withstand such conditions without degradation. Furthermore, the lubricating properties of the additives should be taken into account, as they play a significant role in reducing friction and wear within the gearbox. Other factors to consider include the impact on the viscosity and flow behavior of the polymer, the potential for chemical reactions or incompatibilities with other components in the gearbox, and the overall cost-effectiveness of the additives. By carefully considering these factors, one can select the most suitable polymer additives for gearboxes, ensuring optimal performance and longevity.