On Characterization and Optimization of Engineering Surfaces

Abstract: Swedish manufacturing industry in collaboration with academia is exploring innovative ways to manufacture eco-efficient and resource efficient products. Consequently, improving manufacturing efficiency and quality has become the priority for the manufacturing sector to remain competitive in a sustainable way. To achieve this, control and optimization of manufacturing process and product’s performance are necessary. This has led to increase in demand for functional surfaces, which are engineering surfaces tailored to different applications. With new advancements in manufacturing and surface metrology, investigations are steadily progressing towards re-defining quality and meeting dynamic customer demands. In this thesis, surfaces produced by different manufacturing systems are investigated, and methods are proposed to improve specification and optimization. The definition and interpretation of surface roughness vary across the manufacturing industry and academia. It is well known that surface characterization helps to understand the manufacturing process and its influence on surface functional properties such as wear, friction, adhesivity, wettability, fluid retention and aesthetic properties such as gloss. Manufactured surfaces consist of features that are relevant and features that are not of interest. To be able to produce the intended function, it is important to identify and quantify the features of relevance. Use of surface texture parameters helps in quantifying these surface features with respect to type, region, spacing and distribution. Currently, surface parameters Ra or Sa that represent average roughness are widely used in the industry, but they may not provide adequate information on the surface. In this thesis, a general methodology, based on the standard surface parameters and statistical approach, is proposed to improve the specification for surface roughness and identify the combination of significant surface texture parameters that best describe the surface and extract valuable surface information. Surface topography generated by additive, subtractive and formative processes is investigated with the developed research approach. The roughness profile parameters and areal surface parameters defined in ISO, along with power spectral density and scale sensitive fractal analysis, are used for surface characterization and analysis. In this thesis, the application of regression statistics to identify the set of significant surface parameters that improve the specification for surface roughness is shown. These surface parameters are used to discriminate between the surfaces produced by multiple process variables at multiple levels. By analyzing the influence of process variables on the surface topography, the research methodology helps to understand the underlying physical phenomenon and enhance the domain-specific knowledge with respect to surface topography. Subsequently, it helps to interpret processing conditions for process and surface function optimization. The research methods employed in this study are valid and applicable for different manufacturing processes. This thesis can support the guidelines for manufacturing industry focusing on process and functional optimization through surface analysis. With increase in use of machine learning and artificial intelligence in automation, methodologies such as the one proposed in this thesis are vital in exploring and extracting new possibilities in functional surfaces.