Multiscale characterization and contact performance analysis of machining surfaces

Area of Science:

• Materials Science and Engineering
• Mechanical Engineering
• Surface Metrology

Background:

• Accurate characterization of surface topography is essential for enhancing surface measurement accuracy and analyzing contact performance.
• Existing methods for surface analysis may lack efficiency or accuracy in reconstructing complex topographical features.

Purpose of the Study:

• To develop and validate a novel method for separating and reconstructing the morphological characteristics of actual machined surfaces.
• To evaluate the contact performance of joint surfaces based on reconstructed topographical data.
• To analyze the influence of processing methods and surface roughness on contact parameters.

Main Methods:

• Wavelet transform, layer-by-layer error reconstruction, and signal-to-noise ratio method for separating surface morphological features.
• Reverse engineering for establishing a 3D surface contact model from reconstructed data.
• Finite element method (FEM) for analyzing the impact of processing and roughness on contact parameters.

Main Results:

• A simplified and efficient 3D reconstructed surface model was achieved, outperforming existing approaches.
• Surface roughness was identified as a critical factor influencing contact performance.
• Increased surface roughness led to higher contact deformation, while average contact stress, stiffness, and area decreased.

Conclusions:

• The proposed method effectively reconstructs 3D surface topography from real machining data.
• Surface roughness significantly dictates the contact behavior and performance of joint surfaces.
• The findings provide valuable insights for optimizing manufacturing processes and predicting surface contact performance.