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1

Impact of mixing design parameters on the performance and surface quality of self-compacting concrete filling layers

Zhang Jingyi, Liu He, Zhang Ji

Archives of Civil Engineering

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2026

|

Vol. 72, nr 1

105--119

EN

Construction quality, durability and service life of China Railway Track System III (CRTS III) is influenced by the performance of the self-compacting concrete (SCC) used for filling layer. In this paper, the effect of unit water consumption, sand ratio and water reducer components on working performance of SCC filling layer is studied by laboratory and field tests. Appropriate mix proportion parameters are obtained. The results indicate that unit water consumption can significantly improve the in-service performance of SCC. However, it is essential to consider both the dosage of water-reducing agents and the unit water consumption to ensure the stability of the mixture. Sand ratio of SCC is between 49% and 52% used for filling layer, which have excellent flowability and stability. It is recommended that the content of the defoamer should be 3/1000, and the content of the air-entraining agent should be 5/1000. These research results will play an important role in improving the construction quality of SCC filling layer.

2

Experimental analysis of process parameters in micro-milling of AA6063-T6 using 7% cobalt WC tools

Rathod Vipul Prabhakar, Wankhade Sandeep Haribhau, Kamble Yogesh Ganpat

Advances in Science and Technology. Research Journal

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2026

|

Vol. 20, no. 1

162--182

EN

Recent advancements in ultra-precision machining center have significantly enhanced the capability to produce high-quality aluminium alloy components with improved accuracy, superior surface finish, and extended tool life. The growing demand for precision-manufactured aluminium parts in industries such as aerospace, automotive, biomedical devices, and electronics has increased the need for optimized machining strategies. This study examines the influence of various machining parameters on key performance measures, including surface integrity, dimensional accuracy, and tool wear, during the machining of aluminium alloys. A Definitive Screening Design (DSD) experimental methodology is employed to efficiently evaluate multiple process variables and their interactions while minimizing the number of experimental trials. This approach facilitates the identification of the most significant parameters affecting machining performance, enabling data-driven optimization of the process. This study investigates the micro-milling performance of uncoated WC tools with 7% cobalt binder, unlike conventional 11% cobalt tools, as a suitable choice for machining softer aluminium alloys. The work uniquely integrates experimental trials with ANOVA-based statistical analysis to capture the influence of spindle speed, feed rate, and depth of cut on cutting forces and surface roughness. The findings provide process-level insights and evidence based guidelines for optimizing micro-milling of AA6063-T6. The study highlights that spindle speed is the most critical parameter, contributing nearly half of the performance variations, with optimized settings achieving superior surface finish of 0.0384 µm and reduced cutting forces, thereby extending tool life and ensuring stable, high-quality micro-milling of AA6063-T6 (ASTM).

3

Selected Problems of Effectiveness and Quality in the Dry Rough Milling of Magnesium Alloy AZ91D Using End Mills with Different Helix Angles

Zagórski Ireneusz, Korpysa Jarosław, Kulisz Monika, Skoczylas Agnieszka

Management and Production Engineering Review

|

2025

|

Vol. 16, No. 3

[nr art. 10], s. 1--21

EN

From the point of view of production and manufacturing processes, issues related to surface quality and machining efficiency are very important. This paper presents the results of a study investigating selected problems of quality and efficiency in dry rough milling. Roughness parameters 2D and 3D were analysed. Additionally, 3D surface topography maps and Abbott– Firestone curves were generated. Carbide end mills with different helix angles were used in the study. Experiments were conducted on AZ91D magnesium alloy specimens. The machining process was conducted using high-speed machining parameters. The results showed that the surface roughness of the AZ91D alloy depended to a great extent on the tool geometry and applied machining parameters. Moreover, ANOVA statistical analysis and post-hoc tests (Tukey) were performed to assess the differences between individual groups of the specimens. Additionally, an artificial neural network (ANN) model was developed to predict the Ra parameter, and the results demonstrated its high predictive accuracy (R = 0.966).

4

Influence of machining conditions on the surface quality after circumferential milling of carbon fiber reinforced aluminum laminate

Doluk Elżbieta, Magdziak Marek, Sułkowicz Paweł, Buk Jarosław

Advances in Science and Technology. Research Journal

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2025

|

Vol. 19, no. 10

223--237

EN

FMLs are an increasingly used group of materials due to their properties. Thanks to their advantages, they are used in many areas of industry. An example of this type of material is CARALL. This paper presents the influence of machining conditions on surface quality and cutting forces after circumferential milling of a 3-layer CARALL. The workpieces were formed by combining two different materials: EN-AW 7075-T6 aluminium alloy and Carbon Fiber Reinforced Plastics (CFRP). The effects of cutting speed (vc), feed rate (fz) and helix angle (λ) on material height difference and feed force Ff were investigated. The experiment concluded that poorer surface quality and higher cutting forces were obtained for a tool with a higher helix angle. The parameters to obtain the best surface quality (the lowest material height difference) are cutting speed of 500 m/min, feed rate of 0.08 mm/tooth and helix angle of 20°.The lowest surface accuracy (the highest material height difference) was obtained after machining with the following parameters: cutting speed of 200 m/min, feed rate of 0.08 mm/tooth and helix angle of 35°.

5

Analysis of roundness profile of powder bed fusion additively manufactured samples using hybrid wavelet-Fourier method

Gogolewski Damian, Zmarzły Paweł, Hajnys Jiri, Pagac Marek, Kozior Tomasz

Advances in Science and Technology. Research Journal

|

2025

|

Vol. 19, no. 10

265--277

EN

The aim of the research was to show the feasibility of using a modern, hybrid method of analysis, filtering to detect defects created on samples with a cylindrical shape manufactured by the selected additive technology. The studies focus on diagnostics, assessments of roundness profiles with the modern filtering technique, which employs both wavelet and Fourier transformations. The hybrid combination of two algorithms potentially allows for enhanced, in-depth diagnostics and the identification of the key morphological characteristics that could potentially influence the functional properties of the completed product. An evaluation covered the variability of the irregularities in roundness profiles, taking into account not only the height at which the profile was measured but also the 3D printing angle (orientation). The study showed the importance of verifying the distribution of irregularities across the entire surface of the components, given the substantial disparity in the data in each signal, whereas the employed algorithm further facilitated the accentuation of distinct characteristics of the roundness profiles. The conducted analysis permits carrying out a thorough diagnosis and assessment of the profiles, highlighting the disparity in the character of the roundness profiles as a function of the PBF technology parameters (printing direction) and measurement (location of the profile across the height), which allowed finding functional relationships. The advantage of using the hybrid method in comparison with the classical evaluation method using only Fourier transforms was demonstrated. Therefore, the results presented in the article have the potential for practical use in both the research area and industrial applications and can be supplementary to ASTM/ISO 52901 and ASTM/ISO 52902.

6

The influence of technological parameters of plasma cutting on the quality and surface roughness when cutting thick steel sheets

Góral Tomasz, Dzienniak Damian

Mining Machines

|

2024

|

vol. 42, iss. 2

108--118

EN

The purpose of this study was to analyze the effect of selected parameters on the quality of plasma cutting. The main parameter studied was the cutting speed and how it affects the roughness of the cut surface. The second parameter analyzed was the currentintensity adjusted depending on the thickness of the material being cut, which also has a significant effect on the surface quality of the metal being cut. The evaluation of the quality of the cut surface was carried out on 8, 20, 30 and 35 mm thick sheets of S235JR grade steel. Several samples were selected from each thickness for measurement and testing. The samples were cut with a MAGNUM CUT 160 plasma cutter. The results show that the current intensity and the speed of the torch pass have a significanteffect on the quality of the cut surface.

7

Surface roughness prediction and roughness reliability evaluation of CNC milling based on surface topography simulation

Zhang Ziling, Lv Xiaodong, Qi Baobao, Qi Yin, Zhang Milu, Tao Zhiqiang

Eksploatacja i Niezawodność

|

2024

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Vol. 26, no. 2

art. no. 183558

EN

Surface roughness is influenced by various factors with uncertainty characteristic, and roughness reliability can be used for the assessment of the surface quality of CNC milling. The paper develops a method for the assessment of surface quality by considering the coupling effect and uncertainty characteristicsof various factors. According to the milling kinematics theory, the milling surface topography simulation is conducted by discretizing the cutting edge, machining time, and workpiece. Considering thecoupling effect of various factors, a roughness prediction model isestablished by the SSA-LSSVM, and its prediction accuracy reachesmore than 95%. Then, the roughness reliability model isdevelopedby applying the response surface methodology to achieve the assessment of surface quality. The proposed method is verified by the milling experiments. The maximum values of the relative errors between the simulation and experimental results of the surfaceroughness and roughness reliability are 9% and 1.5% respectively, indicating the correctness of the method proposed in the paper.

8

Experimental investigation and machining analysis of Mg/TiC composites during EDM

Dash Dharmeswar, Devarajaiah Devarasiddappa, Dash Santosh Kumar, Samanta Sutanu, Rai Ram Naresh

Composites Theory and Practice

|

2024

|

R. 24, nr 1

9--16

EN

Electrical discharge machining (EDM) is one of the prominent non-conventional machining processes used to machine metal matrix composites. Mg/TiC composites are found in many industrial applications and conventional machining of the same is highly challenging. This paper aims to study the machinability analysis of Mg/TiC composites using EDM with pulseon time (Ton), pulse-off time (Toff) and input current (I) as the process variables with the material removal rate (MRR) and surface roughness (SR) as the performance measures. Stir cast Mg-alloy reinforced with TiC (0, 5, 10, 15 and 20) by weight was used as the workpiece. The EDM experiments were conducted as per L25 orthogonal array (OA) and the results were analyzed to study the effect of the process variables on MRR and SR. The parametric study showed that SR increases linearly with Ton and is attributed to larger craters produced at a higher pulse energy. MRR was also observed to grows with the rise in Ton as more material melts due to high-intensity pulses. As per the ANOVA results, Ton was found to be the most influential process variable affecting SR and MRR with a 79% and 34% contribution, respectively. Surface morphology investigations using SEM micrographs revealed the presence of globules and sphere-shaped metal deposits and were found responsible for increased SR.

9

Evaluation of selected properties and surface quality of cured pre-impregnated carbon-fiber fabrics after exposure to sulphuric acid

Kojnoková Tatiana, Nový František, Markovičová Lenka, Harea Evgheni, Harea Evghenii

Production Engineering Archives

|

2023

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Vol. 29, Iss. 1

1--6

EN

This paper deals with changes in selected properties of composite material and surface degradation after exposure to an acidic environment. A carbon fiber-reinforced composite (CFRP) produced from prepregs was tested. The weight change, micro-hardness, and surface degradation of the CFRP composite made of cured pre-impregnated laminates were evaluated in this study. Material consisting of a DT121R epoxy resin matrix with high reactivity and high viscosity, with two reinforcing carbon fabrics layers, is characterized by a low value of tensile strength. Evaluation of changes in the material properties was performed before and after exposure to specific environmental conditions, which are achieved by using a chemical solution of 15% H2SO4 at various temperatures. Subsequently, the effect of 15% H2SO4 at various temperatures on the material properties was monitored. The specimens were immersed in the solution for up to 3 and 6 weeks at the temperatures of 23°C, 40°C, and 60°C. It was found out, that the degradation of the composite material is conditioned by the aging of the epoxy resin (matrix). Carbon fibers (reinforcement) are relatively stable. The weight change, micro-hardness, and surface quality depend on the time of exposure to acidic solution and temperature. The micro-hardness tests show a significant influence on exposure time. The biggest changes in weight change and surface quality of the CFRP composite were observed after exposure at the temperature of 60°C.

10

New trends in hybrid finishing processes of metallic additively fabricated parts – a short review

Rech Joel, Grzesik Wit

Journal of Machine Engineering

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2023

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Vol. 23, No. 1

36--46

EN

This comprehensive survey highlights some important finishing processes used in fabricating additively manufactured parts, mainly using SLM (Selective Laser Melting). In practice, there are applied hybrid processes which integrate additive and subtractive componential processes (AM+SM type) or additional finishing processes, mainly based on the electrochemical polishing such as ECP (Electrochemical Cavitation Polishing) and PEMEC (Electrochemical-Mechanical Polishing) ones. On the other hand, AFM (Abrasive Flow Machining) is predominantly recommended for conformal cooling (CC) channels. Some conclusions and future trends in the implementation of special hybrid finishing processes are outlined.

11

Experimental Research on the Influence of Roughness of the Machined Surface of a Part on Galvanization

Ravai Nagy Sandor, Pop Alina Bianca, Nabiałek Marcin, Alexandru Costin, Țîțu Aurel Mihail

Archives of Metallurgy and Materials

|

2023

|

Vol. 68, iss. 4

1591--1595

EN

The purpose of this scientific paper is to follow the influence of thermal galvanizing, as a technological process on the quality of the galvanized surface. The galvanizing technology used and studied involves at the end of the process, the removal of excess zinc from the surface by centrifugation. The zinc layer will be lower than that of simple immersion galvanizing. The measurements were performed following the roughness of the machined surface on a five-Section specimen - each Section being processed with a different cutting regime. The results were analyzed after each operation. The first measurements were made after the turning operation, followed by measurements made after pickling and fluxing and then after thermal galvanizing. Based on the results obtained, the aim was to set up a range of best roughness at which the galvanized part should have a commercial appearance and be made with a cost-effective cutting regime in terms of costs.

12

Effects of EDM on the Chemical Composition and Microstructure of the Surface Layer of Alnico Alloys

Bańkowski Damian, Młynarczyk Piotr, Szwed Bartłomiej

Archives of Foundry Engineering

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2023

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Vol. 23, iss. 2

106--111

EN

This article deals with the effects of electrical discharge machining (EDM) on the chemical composition and microstructure of cast Alnico alloys, i.e., iron-based alloys composed of aluminum, nickel and cobalt. The experiments focused on determining the chemical composition of the surface layer before and after the EDM process. The microstructure of the material altered by the EDM was also examined. The study included measurement of the thickness of the white layer characteristic of EDM. It is evident that low values of the surface roughness parameters can be obtained by correctly selecting the EDM process parameters. The average surface roughness reported in the experiments was 1 μm. The surface roughness measurements were conducted with a Talysurf CCI lite non-contact profiler. The metrological results also indicate that lower surface roughness can be obtained at small discharge energies.

13

Initial assessment of the quality of road surfaces

Szczucka-Lasota Bożena, Waligóra Kamil, Węgrzyn Tomasz, Wszołek Łukasz

Zeszyty Naukowe. Organizacja i Zarządzanie / Politechnika Śląska

|

2022

|

z. 157

571--578

EN

Purpose: The aim of the article is to check the quality of the road and classify the selected road on a four-level scale. Design/methodology/approach: The paper outlines the impact of comprehensive road surface quality management on the safety of vehicles and road users. The basic types of road damage were presented, as well as preliminary diagnostics of a randomly selected national road was carried out. Visual tests were carried out to determine: the type and geometry of the pavement damage, the number of damage, the area covered by the damage. In the article the damage indicators were calculated. The results allowed for the assessment of the quality of the tested pavement and its classification on a four-point scale. Findings: The quality of the road surface was assessed and classified as level C. Research limitations/implications: In the future, it can be suggested to change the methodology of investigate the road. It is proposal to using drone with the application. Practical implications: The research indicates the need to plan the renovation of the road surface and suggests changing the surface material from construction asphalt to the new modified asphalt. Originality/value: The article indicates the need to amend the documents and the current methodology of the procedure.

14

Zgrzewanie oporowe w praktyce inżynierskiej

Lonkwic Paweł, Usydus Ireneusz

Obróbka Metalu

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2022

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nr 2

47--53

PL

Zgrzewanie oporowe, zarówno punktowe jak i liniowe wykorzystywane jest w wielu branżach. Z uwagi na krótki czas operacji obserwuje się szybki wzrostu liczby produkowanych detali tą technologią łączenia. Można ją stosować do łączenia materiałów, tzw. jednoimiennych oraz dwuimiennych (blach o różnych grubościach). W artykule przedstawiono analizę informacji literaturowych oraz rezultaty badań eksperymentalnych z tego zakresu, na podstawie których wskazano czynniki determinujące jakość połączeń wykonanych tą technologią.

EN

Point and linear resistance welding are used in many industries. Due to the short operating time, a rapid increase in the number of parts can be observed with this connection technology. It can be used to connect so-called one-name and two-name materials (sheets with different thicknesses).In this paper analyses literature information and experimental investigations on this domain were consisted. On the basis of experiments factors determining the quality of connections with this technology were identified. resistance welding, surface quality, connection strength.

15

Czynniki determinujące jakość powierzchni po frezotoczeniu

Słomion Małgorzata, Wojciechowski Andrzej, Matuszewski Maciej, Polishchuk Oleg

Obróbka Metalu

|

2022

|

nr 3

40--44

PL

W artykule przedstawiono technologię frezotoczenia. W szczególności scharakteryzowano uwarunkowania technologiczne determinujące jakość powierzchni po obróbce. Uwypuklono najważniejsze zalety i wady frezotoczenia.

EN

In this paper the technology of turn-milling is presented. In particular, the technological conditions determining the quality of the surface after treatment were characterized. The most important advantages and disadvantages of turn-milling are described too.

16

Finishing processes of additively manufactured metallic parts

Grzesik Wit, Rech Joël

Mechanik

|

2022

|

R. 95, nr 10

33--37

EN

This review paper highlights some important finishing processes used in fabricating additively manufactured metalic parts, mainly using SLM (selective laser melting). In practice, there are applied hybrid processes which integrate additive and subtractive componential processes (AM + SM type) or additional finishing processes, mainly based on the electrochemical polishing such as ECP (electrochemical cavitation polishing) and PEMEC (electrochemical-mechanical polishing) ones. For conformal cooling (CC) channels AFM (abrasive flow machining) is predominantly recommended. Some conclusions and future trends in the implementation of hybrid processes are outlined.

PL

W artykule dokonano przeglądu procesów wykańczającego kształtowania złożonych wyrobów metalowych wytwarzanych techniką przyrostową, głównie poprzez selektywne topienie laserowe (SLM). W praktyce stosuje się kombinację kształtowania przyrostowego i ubytkowego (AM + SM) lub dodatkową obróbkę wykańczającą złożonych geometrycznie wyrobów z użyciem procesów konwencjonalnych i hybrydowych w celu uzyskania żądanych jakości powierzchni i właściwości użytkowych, m.in. przetłaczanie ścierne (AFM) do wykańczania powierzchni zewnętrznych oraz polerowanie elektrochemiczne wspomagane ultradźwiękami (ECP) i polerowanie elektrochemiczno-mechaniczne (PEMEC) do wykańczania konforemnych układów chłodzących.

17

Technological methods of ensuring the reliability of lock connections in marine gas turbines

Dvirna Olha, Zembrzuska Natasza

Journal of KONBiN

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2022

|

Vol. 52, iss. 3

149--163

EN

The article presents the test results of the surface quality parameters after broaching of heat-resistant steels of grades: 1.7335 (13CrMo4-5) and 1.4841 (X15CrNiSi25-20). The aim of the work is to determine the technological methods of obtaining the lowest treated surface roughness, surface layer hardening and the elimination of surface defects after broaching. To investigate the influence of cutting conditions (cutting speed, tool geometry and feed) on surface roughness and hardness, the physical modeling method of the broaching was used. As a result of the research, recommendations for improvement of the main parameters of the surface layer quality when broaching samples from selected grades of heat-resistant steels.

PL

W artykule przedstawiono wyniki badań parametrów jakości powierzchni po przeciąganiu stali żaroodpornych gatunków: 1.7335 (13CrMo4-5) i 1.4841 (X15CrNiSi25-20). Celem pracy jest określenie technologicznych sposobów uzyskania najmniejszej chropowatości obrobionej powierzchni, korzystnego poziomu umocnienia warstwy wierzchniej i eliminacji defektów powierzchniowych po obróbce skrawaniem. Aby zbadać wpływ warunków skrawania (prędkości skrawania, geometrii narzędzia i prędkości posuwu) na chropowatość i umocnienia powierzchni, zastosowana została metoda modelowania fizycznego procesu przeciągania. W wyniku badań opracowane zostały rekomendacje dotyczące podniesienia głównych parametrów jakości warstwy wierzchniej podczas przeciągania próbek z wybranych gatunków materiałów żaroodpornych.

18

Ocena jakości ściany wykonanej w technologii druku 3D za pomocą systemu analizy obrazu

Skibicki Szymon

Inżynieria i Budownictwo

|

2022

|

R. 78, nr 3-4

124--127

PL

W artykule przedstawiono pilotażowe badania dotyczące zastosowania systemu analizy obrazu do oceny jakości struktur wykonanych w technologii druku 3D kompozytów cementowych. Zaproponowany algorytm w sposób prawidłowy ocenia jakość powierzchni wydrukowanych elementów. Analiza nieciągłości mieszanki tą metodą może być przydatna nie tylko w ocenie estetyki wykonanych elementów, ale także możliwe jest jej powiązanie z właściwościami mechanicznymi, skurczem oraz trwałością drukowanej struktury.

EN

The paper presents a pilot study on the use of an image analysis system to assess the quality of structures made in the 3D printing technology of cementitious composites. The proposed algorithm correctly evaluated the surface quality of the printed elements. Analysis of the path discontinuity with this method can be useful not only in the assessment of the aesthetics of the manufactured elements, but also it is possible to link it with the mechanical properties, shrinkage and durability of the printed structure.

19

Analysis of surface quality after oxygen cutting

Krawczyk Ryszard, Słania Jacek

Biuletyn Instytutu Spawalnictwa w Gliwicach

|

2022

|

Vol. 66, No. 2

33--41

EN

The article discusses tests concerning surface quality after the oxygen cutting of steel plates of various thicknesses. The study involved visual tests, macro and microscopic metallographic tests as well as hardness measurements and the identification of hardness distribution in the cut zone and in the heat affected zone.

PL

Przedstawiono badania jakości powierzchni po cięciu tlenowym blach stalowych o różnej grubości. Przeprowadzono ocenę wizualną powierzchni próbek po cięciu tlenowym oraz wykonano badania makro- i mikroskopowe zgładów poprzecznych pobranych z próbek. Wykonano pomiary twardości i przedstawiono ich rozkład w strefie cięcia, a także w strefie wpływu ciepła.

20

Machinability Studies on the Turning of Magnesium Metal Matrix Composites

Gobivel K., Vijay Sekar K.S.

Archives of Metallurgy and Materials

|

2022

|

Vol. 67, iss. 3

939--948

EN

Magnesium-based MMCs are widely used in structural-based applications due to their lightweight, high hardness, corrosion and wear resistance. Also, machining is an important manufacturing process that is necessary to ensure dimensional accuracy and produce intricate shapes. In this context, the machining of Magnesium based metal matrix composites is undertaken to study the impact of the cutting parameters on the machinability behaviour. In this work, turning of pure Mg/SiCp on a Lathe is done and an in-depth assessment on the machining forces, machined surface quality, chip microstructure, and tool morphology has been carried out using TiAlN coated tooling insert. The analysis revealed that the thrust force decreased due to the thermal softening of the matrix meanwhile the feed force also followed the similar trend at higher cutting speeds because of the minimized built-up edge and cutting depth whereas principal cutting force was inconsistent at higher cutting speeds. The surface finish was better at high cutting speed - low feed combination. The chip microstructure revealed that gross fracture propagation at the free surface and variations in the shear bands have occurred at different cutting speeds. Tool studies using SEM analysis revealed wear modes like chipping and built-up edge at low cutting speeds, but with a reduced impact at intermediate cutting conditions, whereas abrasion wear was observed predominantly in the tool nose at higher cutting speeds.