This study investigated effects of energy levels, pulse durations, and pulse frequencies during an IPL (Intense Pulsed Light) sintering process on surface morphology and resistance of screen-printed Ag patterns on PET substrates. Surface characteristics, including primary profile (Pa), roughness (Ra), thickness, and sheet resistance, were measured before and after sintering. At fixed energy levels (13.18, 32.96, and 46.14 kW), increasing pulse counts (2, 5, and 7) at 6 ms durations significantly increased Pa and thickness, while Ra was not changed. In contrast, higher pulse counts (4, 10, and 14) at 3 ms durations improved surface roughness by reducing Ra. Statistical analysis (Paired T-test) confirmed these results. Sheet resistance analysis showed that lower pulse counts at 6 ms caused greater variability in resistance, stabilizing with higher counts. At 3 ms, surface resistance decreased with higher pulse counts, showing reduced variability. These results suggest that adjusting pulse conditions and counts during the sintering process can optimize both electrical properties and uniformity. Additionally, morphological changes before and after sintering indicated that these adjustments might influence upper-layer printability in multilayer printing. The study highlights the importance of considering both functional and morphological characteristics during sintering for optimized production of printed electronic devices.
In this study, a new method of bonding CFRP and Al6061-T6 with epoxy adhesive after shot-peening treatment on the surface of Al6061-T6 specimens was proposed to improve bonding strength of a single lap joint between CFRP and Al6061-T6. More specifically, correlation between shot peening coverage on the Al6061-T6 surface and bonding strength with CFRP was experimentally analyzed. Experimental results showed that the surface roughness and the bonding strength increased as the peening time on the surface of Al6061-T6 increased up to a specific peening time (or coverage). However, the surface roughness and bonding strength decreased again under an over-peening condition of 480 seconds (300% coverage) or more. Therefore, it is necessary to search for the optimal peening time that can maximize bonding strength as well as the fatigue life of parts at a peening time between 320 (200%) and 480 s (300%) through additional experiments in future studies.
As the market for minimally invasive procedures developed rapidly, there was an increase in the demand for high-precision, high-performance catheter fabrication technology. Sheath and dilator tubes are essential intervention devices for procedures, in which catheters are used and require precise dimensional accuracy, and uniform roundness and surface roughness. Polyethylene is used in sheath and dilator limitation for processability, which causes low melt flow index and side effects. Therefore, in the extrusion process using polyethylene, it is important to study the manufacturing of tubes with improved roundness and surface roughness. In this study, we proposed a calibrator for precise production with an aim to manufacture 5Fr micro-puncture tubes, and studied the changes in the roundness and surface roughness of tubes by changing the cooling water temperature and water disk thickness. As a result, it was found that the cooling water temperature and wafer disk thickness had an effect on the roundness and surface roughness, and the roundness had an effect on the formation of the wall thickness. Therefore, these experimental results were used as a study for the production of improved Sheath and Dilator tubes.
Drill processing is essential in various industries, such as automobiles and aviation. Carbide is mainly used for drilling, but cermet is also one of the most used materials. Since cermet has low reactivity with iron and low reactivity at high temperatures, excellent surface roughness can be obtained. However, experimental research comparing the performance of carbide and cermet drills is lacking. The purpose of this study was to investigate the difference in the cutting characteristics of cermet and carbide tools. The experimental conditions were feed rates of 150, 200, 250, and 300 ㎜/min and 1,000, 1,500, and 2,000 revolutions per minute. S45C was used as the workpieces. In this study, surface roughness, inner diameter, and spindle load were derived as experimental results and used as indicators to evaluate the performance of carbide and cermet drills. The results showed that the performance of the cermet drill was superior to that of the carbide drill.
As the digitization of the manufacturing process is accelerating, various data-driven approaches using machine learning are being developed in chemical mechanical polishing (CMP). For a more accurate prediction in contact-based CMP, it is necessary to consider the real-time changing pad surface roughness during polishing. Changes in pad surface roughness result in non-uniformity of the real contact pressure and friction applied to the wafer, which are the main causes of material removal rate variation. In this paper, we predicted the material removal rate based on pressure and surface roughness using a deep neural network (DNN). Reduced peak height (Rpk) and real contact area (RCA) were chosen as the key parameters indicative of the surface roughness of the pad, and 220 data were collected along with the process pressure. The collected data were normalized and separated in a 3 : 1 : 1 ratio to improve the predictive performance of the DNN model. The hyperparameters of the DNN model were optimized through random search techniques and 5 cross-validations. The optimized DNN model predicted the material removal rate with high accuracy in ex-situ CMP. This study is expected to be utilized in data-driven machine learning decision making for cyber-physical CMP systems in the future.
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Precision Engineering and Intelligent Technologies for Predictable CMP Somin Shin, Hyun Jun Ryu, Sanha Kim, Haedo Jeong, Hyunseop Lee International Journal of Precision Engineering and Manufacturing.2025; 26(9): 2121. CrossRef
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The incremental sheet forming (ISF) process is a method of forming a metal sheet with a machine tool, such as a CNC or robot arm. In this study, the surface characteristics of the ISF process using the ball type tool and the conventional hemispherical tool were analyzed. Comparative experiments were conducted with the same size of the hemispherical tool and ball type tool. In experiments, the tool feed rate and spindle were fixed, and the step down was set up with seven levels. The surface profiles and roughness such as Ra and Rz after the ISF process with different values of the step down were compared. Additionally, the surface morphologies were analyzed through the scanning electron microscope. A ball type tool which can move and roll, can reduce the effect of friction effectively. As a result, the ISF process with a ball type tool can greatly reduce the damage of the surface of the product.
In this paper, when the finishing process is performed on the additive by FDM type, the optimal parameter set of the additive-finishing design parameters to improve the surface quality and the verification of the finishing effect are described. Additive design parameters such as nozzle diameter and layer height and finishing design parameters such as depth of cut and feed rate have a significant influence on the printing time and surface roughness of the sculpture. So, we define the major additive-finishing design parameters expected to affect the results. So, we define the major additive-finishing design variables that expected to affect the experimental results. And to confirm how much they affect the results with the minimum number of experiments, the sensitivity analysis of the design parameters was performed through the level average analysis of the Taguchi method. As a result, compared to the surface roughness and additive time when only high-quality sculpture was performed, and it was confirmed that the printing time improved up to 70% and the surface roughness improved up to 87% for the additive-finishing sculpture performed with the optimal combination of design parameters.
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Compacted graphite iron (CGI) has been widely used in the automobile industry because of its good mechanical properties. CGI has better strength as compared to grey iron due to its internal structure. It includes graphite particles, which enhance the adhesion between graphite and iron. However, the material characteristics can negatively affect the machinability. In this study, cryogenic milling was performed for CGI450. It is well known that cryogenic machining is effective in improving the machinability. The process included spraying liquid nitrogen as a cryogenic coolant, and the influences on machinability were experimentally investigated with a focus on the cutting force and surface roughness. When liquid nitrogen was sprayed, the cutting force was slightly increased due to the cold-strengthening effect. On the other hand, surface roughness was dramatically decreased by 44.7% as compared to dry milling because brittleness of work material was increased by cryogenic coolant spraying.
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The objective of the present study was to investigate the relationship between surface roughness and touch perception of surfaces with randomly spaced, irregular features. Two sets of specimens with top surfaces consisting of triangular peaks and valleys were modeled and 3D-Printed by varying the height of the peak, the depth of the valley, and the width between two intersections of the peak or valley with the center line. For one set of specimens, values of these variables were kept constant within a specimen but varied across specimens. For the other set of specimens, values of these variables were randomly selected in given ranges within a specimen while ranges were varied across specimens. The level of touch perception of each specimen was then measured using a questionnaire consisting of 16 adjectives related to touch perception and a 7-point Likert scale. Measured data were statistically analyzed and compared between different sets of specimens. Results indicated that it was inappropriate to directly apply findings of the previous studies for surfaces with regularly spaced, geometrically well-defined features to surfaces with randomly spaced, irregular features.
Recently, interest in astronomy has increased internationally, and the technological development of lenses for large space telescopes is progressing. The multi-order diffractive engineered (MODE) lenses can make a large space telescope light and thin. However, because glass lenses are difficult to machine, we have adopted a method of molding at high temperature and high pressure. The STAVAX is commercially available chrome alloy stainless steel, and it is applied as various mold materials. The ultrasonic vibration cutting was adopted for ultra-precision machining because the tool wear is severe when cutting the STAVAX with a diamond tool. To achieve a flat surface for smooth ultrasonic vibration cutting, we performed a precise shape cutting using a CBN tool and confirmed and observed changes in the surface roughness and hardness depending on the cutting conditions. The ultrasonic vibration cutting was performed on the surface of the machine using a CBN tool, and the surface roughness was observed. It was confirmed that the surface roughness was impacted by the surface hardness. The specimens with low surface hardness showed the highest surface roughness at approximately 3 nm.
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With the development of 3D printing technology, its applications are expanding. However, 3D printed parts present a challenge in achieving high-quality surface roughness because of stair stepping problems. With the recent application of 3D printing in electronics and the visibility of flow in microfluidic systems, high-quality surface roughness is needed. Chemical mechanical polishing (CMP), one of semiconductor fabrication processes, has the longest planarization length in terms of productivity among existing planarization methods. In this study, we investigate friction characteristics of polishing of ABSLike resin material printed by the Stereolithography Apparatus (SLA). At the polishing of ABS-Like resin, the friction force has a high value at the beginning of polishing, but it stabilizes as processing progresses because of the effect of waviness on the printed material. The surface roughness (Sa and Sz) reduction and the glossiness of ABS-Like resins after polishing appear to be related to the reduction of the Shore D hardness resulting from the rise in the polishing process temperature caused by friction during polishing.
This paper is a study of the machining characteristics, cutting force and surface roughness of a turning center by laserassisted machining. The laser-assisted machining (LAM) is an effective method to improve the machinability of difficult-tocut materials. The LAM has recently been studied for various machining processes, but the research on the threedimensional and turning-center machining is still insufficient. In this study, a machining experiment of the turning-center process was performed by the laser-assisted machining with Inconel 718. Before the machining experiment, performed to thermal analysis was for a selected to effective depth of cut. The cutting force and surface roughness were compared and analyzed. The machining experiment confirmed that the machinability was improved in the LAM.
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Rolled and extruded aluminum (Al) products have been widely used in heat exchanging systems using the boiling heat transfer (BHT) mechanism. The BHT coefficient can be increased on a rough surface due to the activation of the nucleation sites. In this study, the BHT characteristic of an Al plate with directional surface roughness (bare Al plate), which was generated in rolling or extrusion process, was measured and compared with the polished Al plates with non-directional surface roughness. The BHT coefficient of polished Al plate was increased with increasing surface roughness, saturated at ~300 nm (Sa). Although the surface roughness of the bare Al plate was 380-430 nm (Sa), the BHT coefficient of bare Al plates were lower than the polished Al plates with similar surface roughness. To examine the lower BHT coefficient of bare Al plate, the directional surface roughness was characterized by vertical and horizontal surface roughness values to the production direction, and we experimentally concluded the lower surface roughness value (horizontal surface roughness) was the dominant factor for the BHT characteristic of a rolled or extruded Al plate with directional surface roughness.
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In laser polishing, a laser beam is used to melt the surface of a work piece to improve surface quality. An optimum combination of process controlling parameters and state of laser beam output is the key strength of laser polishing. Laser beam output power, feed rate, path interval, and spot size are critical parameters in the laser polishing process effect on the thermal state of surface quality. In this study, experimental tests demonstrate that it is an optimum value of the proper processes condition in the pulse laser and CW laser system. The proposed dominant controlling parameters, method for examining morphology; several experimental conditions; and details from performance improvement of surface roughness are presented.
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Carbon Fiber Reinforced Plastics (CFRP) is an encouraging material for aerospace and automotive industries due to its light weight and high strength. Aerospace parts require precise dimensional tolerance and high machined surface quality for safety and reliability. Routing process is needed to produce satisfactory dimensional accuracy of CFRP parts. Machining defects of routing process are related to the cutting mode with respect to cutting angle and bonding strength between carbon fibers and polymer matrix. When the polymer matrix is transformed from polymer to amorphous state, bonding strength is declined. Therefore, cutting temperature is a critical parameter for CFRP machining process because glass transient temperature is relatively low. In this paper, cutting temperature was measured using thermal imaging camera. Machined surface roughness and maximum fiber pull-out depth were analyzed with respect to feed, spindle speed, and laminate structure.
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