Combining surface measurement data from individual measurements of surface fragments is an issue that has been recognized for flat surfaces. The connection takes place on the principle of making ‘overlap’ measurements according to a specific measurement strategy, and then the algorithm synthesizes the measurement data for the common part (data fusion). This paper presents a method of combining partial data into one larger set using image processing methods. The purpose of the analysis is to combine surface data of a more complex shape in terms of surface roughness and waviness. A successful attempt was made to combine surface measurement data located on a cylindrical surface – convex surface. A rotated table was designed and used for surface data acquisition. The datasets were acquired with the use of CCI 6000 (366 μm – 366 μm) with the assumed overlapping of at least 20%. The measurement datasets were first pre-processed: filling in non-measured points, levelling and form re- moving were applied. For such processed datasets, the common part was identified (data registration) and then the data fusion was performed. An example of stitching the surface datasets shows usefulness of the presented methodology.
The production process of prosthetic restorations runs in two stages. In the first stage, the prosthetic foundation is produced of metal alloys. In the second stage, a facing material is applied on the produced element. In both stages, the wettability is significantly important, as well as the free surface energy relating to it. The quality of the obtained cast depends on the surface phenomena occurring between the metal alloy and the material of which the casting mould is made. The performed examinations also point to a relation between the ceramics joint and the base, depending on the wetting angle. The aim of the presented paper was to examine influence of the composition of a Ti(C,N)-type coating on bases made of the Ni-Cr prosthetic alloy on the wettability and the surface free energy. The test material were disks made of the Ni-Cr alloy with the diameter of 8 mm. The disks were divided into five groups, which were covered with Ti(C,N) coatings, with different amounts of C and N in the layer. In order to determine the surface free energy (����), the wetting angle was measured. Two measure liquids were applied: distilled water and diiodomethane. The obtained results of the measurements of the water-wetting angles suggest that together with the increase of the ratio of nitrogen to carbon in the Ti(C,N) coating, the surface hydrophobicity increases as well. In all the samples, one can see a large difference between the energy values of the polar and the apolar components. The high values of the polar components and the low values of the apolar ones make it possible to conclude that these surfaces exhibit a greater affinity to the polar groups than to the apolar ones. On the basis of the analysis of the surface free energy, one can state that covering the alloy with Ti(C,N)-type coatings should not decrease the adhesion of the ceramics to the alloy, whereas TiC coatings should lead to the latter’s improvement. Due to their hydrophilicity, TiC coatings should decrease the adhesion of bacteria to the surface and hinder the formation of a bacterial biofilm.
Obtaining discrete data is inseparably connected with losing information on surface properties. In contact measurements, the ball tip functions as a mechanical-geometrical filter. In coordinate measurements the coordinates of the measurement points of a discrete distribution on the measured surface are obtained. Surface geometric deviations are represented by a set of local deviations, i.e. deviations of measurement points from the nominal surface (the CAD model), determined in a direction normal to this surface. The results of measurements depend both on the ball tip diameter and the grid size of measurement points. This article presents findings on the influence of the ball tip diameter and the grid size on coordinate measurement results along with the experimental results of measurement of a free-form milled surface, in order to determine its local geometric deviations. One section of the surface under research was measured using different measurement parameters. The whole surface was also scanned with different parameters, observing the rule of selecting the tip diameter d and the sampling interval T in the ratio of 2:1.
Computer-aided tools help in shortening and eradicating numerous repetitive tasks that reduces the gap between digital model and actual product. Use of these tools assists in realizing free-form objects such as custom fit products as described by a stringent interaction with the human body. Development of such a model presents a challenging situation for reverse engineering (RE) which is not analogous with the requirement for generating simple geometric models. Hence, an alternating way of producing more accurate three-dimensional models is proposed. For creating accurate 3D models, point clouds are processed through filtering, segmentation, mesh smoothing and surface generation. These processes help in converting the initial unorganized point data into a 3D digital model and simultaneously influence the quality of model. This study provides an optimum balance for the best accuracy obtainable with maximum allowable deviation to lessen computer handling and processing time. A realistic non trivial case study of free-form prosthetic socket is considered. The accuracy obtained for the developed model is acceptable for the use in medical applications and FEM analysis.
The paper presents the problem of assessing the accuracy of reconstructing free-form surfaces in the CMM/CAD/CAM/CNC systems. The system structure comprises a coordinate measuring machine (CMM) PMM 12106 equipped with a contact scanning probe, a 3-axis Arrow 500 Vertical Machining Center, QUINDOS software and Catia software. For the purpose of surface digitalization, a radius correction algorithm was developed. The surface reconstructing errors for the presented system were assessed and analysed with respect to offset points. The accuracy assessment exhibit error values in the reconstruction of a free-form surface in a range of ± 0.02 mm, which, as it is shown by the analysis, result from a systematic error.
Geometric deviations of free-form surfaces are attributed to many phenomena that occur during machining, both systematic (deterministic) and random in character. Measurements of free-form surfaces are performed with the use of numerically controlled CMMs on the basis of a CAD model, which results in obtaining coordinates of discrete measurement points. The spatial coordinates assigned at each measurement point include both a deterministic component and a random component at different proportions. The deterministic component of deviations is in fact the systematic component of processing errors, which is repetitive in nature. A CAD representation of deterministic geometric deviations might constitute the basis for completing a number of tasks connected with measurement and processing of free-form surfaces. The paper presents the results of testing a methodology of determining CAD models by estimating deterministic geometric deviations. The research was performed on simulated deviations superimposed on the CAD model of a nominal surface. Regression analysis, an iterative procedure, spatial statistics methods, and NURBS modelling were used for establishing the model.
A layered sensor structure of metal-free phthalocyanine H2Pc (~160 nm) with a very thin film of palladium (Pd ~20 nm) on the top, has been studied for hydrogen gas-sensing application at relatively low temperatures of about 30°C and about 40°C. The layered structure was obtained by vacuum deposition (first the phthalocyanine Pc and than the Pd film) onto a LiNbO3Y- cut Z-propagating substrate, making use of the Surface Acoustic Wave method, and additionally (in this same technological processes) onto a glass substrate with a planar microelectrode array for simultaneous monitoring of the planar resistance of the layered structure. In such a layered structure we can detect hydrogen in a medium concentration range (from 0.5 to 3% in air) even at about 30°C. At elevated temperature up to about 40°C the differential frequency increases proportionally (almost linearly) to the hydrogen concentration and the response reaches its steady state very quickly. The response times are about 18 s at the lowest 0.5% hydrogen concentration to about 42 s at 4% (defined as reaching 100% of the steady state). In the case of the investigated layered structure a very good correlation has been observed between the two utilized methods - the frequency changes in the SAW method correlate quite well with the decreases of the layered structure resistance.
Local geometric deviations of free-form surfaces are determined as normal deviations of measurement points from the nominal surface. Different sources of errors in the manufacturing process result in deviations of different character, deterministic and random. The different nature of geometric deviations may be the basis for decomposing the random and deterministic components in order to compute deterministic geometric deviations and further to introduce corrections to the processing program. Local geometric deviations constitute a spatial process. The article suggests applying the methods of spatial statistics to research on geometric deviations of free-form surfaces in order to test the existence of spatial autocorrelation. Identifying spatial correlation of measurement data proves the existence of a systematic, repetitive processing error. In such a case, the spatial modelling methods may be applied to fitting a surface regression model representing the deterministic deviations. The first step in model diagnosing is to examine the model residuals for the probability distribution and then the existence of spatial autocorrelation.