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Laser Micromachining for Polymer Surface Topography Design

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Published on: September 19, 2025

A Novel Simulation Method of Micro-Topography for Grinding Surface.

Qi An¹, Shuangfu Suo¹, Yuzhu Bai¹

¹Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China.

Materials (Basel, Switzerland)

|September 28, 2021

Summary

A new method simulates grinding surface microtopography using wavelet analysis to decompose and combine surface data. This approach accurately reconstructs surface textures, crucial for advanced manufacturing processes.

Keywords:

frequencies extraction grinding surface microtopography simulation method

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Area of Science:

Surface Metrology
Computational Engineering
Materials Science

Background:

Accurate simulation of grinding surface microtopography is essential for predicting and optimizing manufacturing processes.
Existing methods may not fully capture the complex multiscale nature of surface topography.

Purpose of the Study:

To propose a novel simulation method for grinding surface microtopography.
To accurately generate simulation topography by combining measured and geometrically simulated data.
To validate the method's accuracy by comparing roughness parameters.

Main Methods:

Wavelet analysis for multiscale decomposition of measured topography into high-frequency band (HFB), theoretical frequency band (TFB), and low-frequency band (LFB).
Extraction of HFB and LFB to create a digital combination model.
Integration of the digital combination model with geometrically simulated theoretical topography to generate simulation topography.

Main Results:

The proposed method successfully generated simulation topography of grinding surfaces.
Comparison of roughness parameters (Sa, Sq, Ssk, Sku) between measured and simulated topographies showed high accuracy.
Maximum relative errors for Sa, Sq, Ssk, and Sku were 1.79%, 2.24%, 4.69%, and 4.73%, respectively.

Conclusions:

The wavelet-based simulation method is feasible and accurate for generating grinding surface microtopography.
This method provides a reliable tool for surface analysis and process optimization in grinding.
The approach effectively captures multiscale features of surface topography for realistic simulations.