研究目的
To demonstrate the combined use of white light interferometry and MountainsMap? software for accurately measuring indentation diameters to examine static load capacity of bearings and for characterizing machined surfaces to optimize surface finish on orthotic knee joints.
研究成果
The combined use of white light interferometry and MountainsMap? software significantly enhances measurement accuracy for surface characteristics. In case study 1, static load capacity of bearings was found to be lower than industry standards, with Hertzian stress limits between 5,102 MPa and 6,205 MPa. In case study 2, surface finish parameters for orthotic knee joints were optimized with improvements up to 36%. This demonstrates the effectiveness of modern topography techniques in improving product quality and performance in engineering applications.
研究不足
The study is limited to specific materials (AISI 52100 steel and A6061-T6 aluminum) and applications (bearings and orthotic knee joints). The accuracy relies on the capabilities of WLI and MountainsMap?, which may have inherent measurement uncertainties. The experiments are conducted in controlled laboratory settings, and results may not generalize to all industrial conditions.
1：Experimental Design and Method Selection:
The study involves two case studies. Case study 1 uses indentation tests on bearing materials to measure static load capacity, comparing results with Hertz theory and finite element analysis. Case study 2 uses a design of experiments (DOE) with Taguchi methodology to optimize surface finish parameters in CNC milling of orthotic knee joints. White light interferometry (WLI) and MountainsMap? software are employed for non-contact, high-precision surface measurements and analysis.
2：Sample Selection and Data Sources:
For case study 1, samples include AISI 52100 steel plates and balls with hardnesses ranging from 56 to 66 HRC, heat-treated and tempered. For case study 2, samples are orthotic knee joints made from A6061-T6 aluminum, machined using various parameters.
3：List of Experimental Equipment and Materials:
Equipment includes a white light interferometer (specific model not mentioned), MountainsMap? software, Instron testing machine (100 kN capacity with Bluehill 3 Software), Mitutoyo hardness testing machine, Struers Abrapol-20 Polisher, HAAS CNC milling VF-2TR machine, and master CAM 8.0 software. Materials include AISI 52100 steel, A6061-T6 aluminum, and various cutting tools and abrasives.
4：0 software. Materials include AISI 52100 steel, A6061-T6 aluminum, and various cutting tools and abrasives.
Experimental Procedures and Operational Workflow:
4. Experimental Procedures and Operational Workflow: In case study 1, indentation tests are conducted with varying loads on ball-plate pairs, and measurements are taken using WLI and analyzed with MountainsMap?. In case study 2, CNC milling experiments are performed based on a DOE table, surface finish is measured at multiple points using WLI, and parameters are analyzed with MountainsMap?.
5：Data Analysis Methods:
Data analysis involves comparing indentation diameters with theoretical models (Hertz theory and FEA) in case study 1, and optimizing surface roughness parameters using statistical methods (e.g., Taguchi) in case study 2. MountainsMap? software is used for image enhancement, filtering, and parameter extraction.
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