Search Results (104)

The assembly interface topography of precision machinery exhibits complex multi-scale geometric features, including roughness, waviness, and form error, which critically influence assembly accuracy and tolerance analysis. To address the lack of adaptivity in existing separation criteria, this paper proposes a multi-scale digital modeling approach oriented toward tolerance analysis of precision assembly interfaces, based on a fractal-wavelet framework. Firstly, multiple Weierstrass–Mandelbrot functions with independent fractal dimensions are superposed to construct a multi-fractal topography model with controllable multi-scale characteristics, grounded in the power spectral density energy additivity property. Subsequently, wavelet functions are employed to hierarchically decompose the topography height field information. The effects of the compact support length and vanishing moments of the wavelet functions on the decomposition performance are analyzed to establish a clear basis for their selection. Finally, an adaptive multi-scale separation criterion based on wavelet energy K-means clustering is then proposed, with the optimal number of scale classes determined by maximizing the silhouette coefficient, eliminating reliance on empirical thresholds. Case study results show that the fused waviness-and-form-error model retains 94.8% of the original energy while reducing convex peak count by over 90%, significantly simplifying the interface microstructure for downstream tolerance computation. The proposed method provides a high-fidelity, adaptive digital foundation for assembly accuracy prediction of precision interfaces. Full article

Surface quality of machined wood-based panels plays a key role in subsequent processing and product performance; however, its formation during CNC edge milling remains insufficiently understood, particularly for materials with different structural characteristics, including recycled content. This study investigates the influence of feed per tooth, milling strategy, and material structure on surface quality during CNC edge milling of particleboards manufactured from alternative lignocellulosic resources. Six board variants were experimentally produced and machined on a five-axis CNC machining center Morbidelli m100 using a single-edge milling cutter, with feed per tooth varied at three levels and both climb and conventional milling strategies applied. Surface quality was evaluated using a non-contact 3D optical profilometer Keyence VR-6000, and roughness (R_a) and waviness (W_z) parameters were analyzed. The results showed that surface roughness increased with increasing feed per tooth for all materials, with an increase of approximately 30%–70%. Statistical analysis confirmed a significant effect of feed per tooth and material type, while milling strategy and its interaction with material were not statistically significant. Materials with higher surface heterogeneity (CVR_a) showed increased roughness and greater sensitivity to feed. A statistically significant positive relationship was found between surface heterogeneity (CVR_a) and roughness sensitivity (ΔR_a), indicating that materials with higher surface heterogeneity (CVR_a), which likely reflects variability in their internal structure, are more sensitive to changes in feed per tooth. Full article

Alcoholic liver injury (ALI) represents a global public health crisis with limited therapeutic options. Polysaccharides from edible mushrooms have emerged as promising candidates for liver protection due to their multifaceted biological activities and low toxicity. A mouse model of ALI was established to investigate the protective effect of Agaricus subrufescens polysaccharide on liver injury. The polysaccharide exhibited a non-triple-helix structural, characterized by a rough surface morphology, crack-like features, and a wavy strip structure. The body growth, liver index, serum and liver biochemical parameters, hepatic histopathological characteristics, and hepatic mRNA levels were investigated. The results demonstrated that A. subrufescens polysaccharide significantly alleviated liver injury, decreased serum levels of ALT by 36.22% and AST by 31.65%, lowered hepatic MDA content by 33.19%, and increased the activities of antioxidant enzymes, including SOD, GSH-P_X, and Cat by 12.04%, 9.76% and 18.45%, respectively. Meanwhile, the polysaccharide also regulated the mRNA expression of key genes involved in fatty acid metabolism, oxidative stress, and inflammatory responses. These findings provide theoretical evidence for the efficacy of A. subrufescens polysaccharide against alcohol-induced liver injury. Full article

The proper selection of surface topography (ST) parameters is crucial for ensuring the effective performance of machine components, including their wear and corrosion resistance. In the literature, research on the ST of hardened stainless steels (SSs) after finish turning using cubic boron nitride (CBN) inserts, as well as comparisons with cemented carbide (CC) inserts depending on cutting parameters, is still limited. In this study, the ST of X20Cr13 martensitic hardened SS under dry finish turning with various cutting speeds and feed rates was investigated. Experiments were conducted using a CNC lathe with CBN and CC inserts. A Sensofar S Neox 3D optical profilometer was employed to characterize the ST features, including height surface roughness (SR) parameters, SR profiles, and 2D and 3D surface images. The Parameter Space Investigation method was used to design the experimental plan. For both CBN and CC inserts, the feed rate was the dominant factor influencing the overall SR, described by the Sa and Sq parameters. The extreme parameters Sp, Sv, and Sz were determined by the relationship between feed rate and cutting speed. With appropriately selected turning parameters, it is possible to obtain low Sa values (0.4–0.6 µm), which can eliminate the need for grinding operations. CBN inserts ensured a more regular shape of the ST, while CC inserts contributed to a wavy surface characteristic, associated with more intense plastic deformation. However, low Sa values may be accompanied by isolated peaks, indicating that this parameter does not always fully reflect the presence of extreme micro-irregularities. On the machined surfaces, adhesive bonds of chips and cutting tool material were observed. In addition, micro-scratches were registered for CBN inserts, and a side flow phenomenon for CC inserts. The results confirm that dry turning of hardened SSs can be effectively performed using both CC and CBN inserts. Full article

In mechanical engineering, interest in reliable and practicable technologies for nano- and microstructuring of tool surfaces is increasing. Femtosecond laser structuring offers a promising approach that combines high processing speeds with high precision. However, a knowledge gap remains regarding the optimal process parameters for achieving specific surface patterns on hot-work tool steel substrates. The current study aims to investigate the effects of laser scanning parameters on the formation of self-organized surface structures and the resulting topography and morphology. Therefore, samples were irradiated using a 300 fs laser with linearly polarized light (λ = 1030 nm). Scanning electron microscopy revealed four structure types: laser-induced periodic surface structures (LIPSSs), micrometric ripples, micro-crater structures, and pillared microstructures. The results for surface area and line roughness indicate that high laser pulse overlaps lower the strong ablation threshold more effectively than high scanning line overlaps, promoting the formation of pillared microstructures. For efficient ablation and increased surface roughness, higher pulse overlaps are therefore advantageous. In contrast, at low fluences, higher scanning line overlaps support a more homogeneous formation of nanostructures and reduce waviness. Full article

The success of acid stimulation in tight carbonate reservoirs relies on the formation of non-uniform etching on fracture walls. However, existing research on the influence of the fracture surface morphology on non-uniform etching and fracture conductivity predominantly employed non-replicable tensile fracture surfaces. Previous studies were unable to use identical fracture surfaces to conduct single-factor analysis and clarify the impact of roughness. This study utilized digital engraving technology to fabricate multiple artificial carbonate rock samples with a homogeneous lithology and completely consistent fracture surface morphology. Using the Triangular Prism Method (TPM), the initial fracture roughness of the rock samples was decomposed into large-scale waviness and small-scale unevenness. Through controlled injection parameters, single-factor acid etching experiments were conducted. For the first time, the effects of large-scale waviness and small-scale unevenness on acid etching were investigated, along with the influences of the acid injection rate and injection time. The existence of an optimal injection rate and an optimal injection time was clarified. The results demonstrate that the engraved carbonate samples’ surfaces exhibit good consistency with the original natural fracture surfaces. The acid solution acts to shave the “peaks” and deepen the “valleys” of rough fractures. The large-scale waviness characteristics of the initial rough surfaces determine the overall post-etching morphology, leading to poor surface contact within the fracture. This is the primary reason for the high fluid flow capacity of acid-etched fractures under low closure stresses. However, the small-scale unevenness characteristics of the initial rough surfaces determine the formation and the distribution of small protruding support points on the post-etching surface. This is the primary reason for the retention of high conductivity in acid-etched fractures under high closure stresses. An increase in the acid injection rate or acid injection time does not lead to a linear decrease in linear roughness, surface mismatch, or fracture aperture. A critical acid injection rate or critical acid injection time exists. Optimizing the injection rate or time can achieve an ideal etching morphology—the protrusions formed by punctate etching enable the fractures to maintain a certain level of conductivity even under a high closure stress of 55.2 MPa, while channel etching can increase the conductivity under high closure stress by 20–25%, providing a key direction for optimizing acid etching effects. Full article

With the rapid development of Head-Up Display (HUD) technology for vehicles, optical freeform mirrors, as its core optical components, are crucial for achieving system compactness and high imaging quality. However, their complex surface shapes and large-aperture characteristics pose significant challenges to ultra-precision manufacturing. This study presents a systematic optimization framework for the ultra-precision machining of HUD optical freeform mold cores, integrating surface design, tool path planning, vibration analysis, and process parameter optimization. Firstly, based on the XY polynomial freeform surface model, an off-axis three-mirror HUD system was designed, and the surface parameters and machining dimensions of the mold core were determined. For the Single-Point Diamond Turning (SPDT) Slow Tool Servo (STS) process, a hybrid trajectory planning method combining equidistant projection and cubic spline interpolation was proposed to ensure the smoothness and accuracy of the tool path. Through theoretical analysis and experimental verification, the selection criteria for tool parameters such as tool nose radius and effective cutting angle were clarified, and the mechanistic impact of Z-axis vibration on surface roughness and waviness was quantitatively revealed. Finally, through ultra-precision turning experiments and on-machine measurement, a high-precision freeform surface mold core was successfully fabricated. This validates the effectiveness and feasibility of the proposed process solution and provides technical support for the high-quality manufacturing of HUD optical elements. Full article

Remote sensing enables large-scale, image-based assessments of river dynamics, offering new opportunities for hydrological monitoring. We present a publicly available dataset consisting of 281,024 satellite and aerial images of U.S. rivers, constructed using an Application Programming Interface (API) and the U.S. Geological Survey’s National Hydrography Dataset. The dataset includes images, primary keys, and ancillary geospatial information. We use a manually labeled subset of the images to train models for detecting rapids, defined as areas where high velocity and turbulence lead to a wavy, rough, or even broken water surface visible in the imagery. To demonstrate the utility of this dataset, we develop an image segmentation model to identify rivers within images. This model achieved a mean test intersection-over-union ($IoU$) of 0.57, with performance rising to an actual $IoU$ of 0.89 on the subset of predictions with high confidence (predicted $IoU$ > 0.9). Following this initial segmentation of river channels within the images, we trained several convolutional neural network (CNN) architectures to classify the presence or absence of rapids. Our selected model reached an accuracy and F1 score of 0.93, indicating strong performance for the classification of rapids that could support consistent, efficient inventory and monitoring of rapids. These data provide new resources for recreation planning, habitat assessment, and discharge estimation. Overall, the dataset and tools offer a foundation for scalable, automated identification of geomorphic features to support riverine science and resource management. Full article

This paper presents an experimental study on the influence of surface texturing on friction and film thickness in the hydrodynamic lubrication regime. Using a pin-on-disk tribometer equipped with light-induced fluorescence microscopy, simultaneous measurements were conducted on smooth and textured samples under parallel and inclined surface conditions. The circular faces of the pins were partially or fully covered by circular laser-machined textures consisting of dimples with depths of 5 or 10 µm, diameters of 50 or 100 µm, and coverage density of 20%. The results demonstrate that while texturing significantly reduces friction and increases film thickness in parallel gaps, with partial inlet coverage being the most effective, its impact is minimal in inclined wedge gaps. The study further reveals that the global geometric wedge dominates over texture effects in inclined contacts and that in-texture cavitation, prevalent in parallel conditions, is suppressed by surface inclination. Three distinct contributions of the textures were discussed: a global hydrodynamic effect, a local hydrodynamic effect, and the influence of surface non-flatness (waviness). The findings suggest that texturing is primarily beneficial for acting as a pseudo-wedge or as surface roughness in contacts where a physical wedge is absent. Full article

Surface roughness (SR), most often computed from a digital elevation model (DEM), is a fundamental concept in geomorphometry, with significant applications across the earth sciences and ecology. However, its analysis remains fragmented, lacking a unified conceptual and methodological framework within geomorphometry. This review synthesizes the current state of surface roughness research, highlighting persistent challenges that stem from this disunity. Key issues include a pervasive lack of consensus on terminology and definitions, frequent misuse of standardized indices, and difficulty in selecting appropriate analytical scales and metrics for specific landscapes and research questions. A major impediment to progress is the absence of benchmark datasets, which are crucial for the rigorous evaluation and comparison of both established and novel roughness metrics. Furthermore, we argue that in geomorphometry, roughness is best conceptualized as surface texture (ST), encompassing a multitude of terrain patterns across scales. Consequently, effective analysis often requires multiscale approaches and the development of new indices capable of quantifying specific textural features. We emphasize, for instance, the need for metrics based on robust statistical estimators, such as MAD or the Radial Roughness Index (RRI), to reliably characterize complex, heterogeneous terrain derived from high-resolution DEMs. These arguments are substantiated with computational examples comparing a range of metrics, from popular basic indices to more complex alternatives. This review aims to consolidate discourse on surface roughness and chart a path toward more robust, standardized, and interpretative analytical practices. Full article

Fine-grained Nb metal sheets were successively laser macro- and micro-polished for a potential use of the so-prepared materials in superconducting radiofrequency cavities in particle accelerators. The laser-treated Nb surfaces were investigated by a combination of white light interferometry, optical profilometry, electron microscopy with X-ray spectroscopy, and X-ray diffraction to study the influence of the conditions during the laser treatments on the resulting surface topography, the crystallographic structure, and the chemical composition of the material samples. For optimum polishing conditions, smooth, wavy surfaces with a minimum surface roughness could be achieved. However, local defects such as carbon contamination, as well as holes and cracks in the surface, were found. For the different prepared surfaces, the maximum acceleration field gradients, i.e., the onset fields for field emission (E_On), were determined, indicating that for smooth surface regions without defects, E_On may reach values of up to almost 1 GV/m, while for the pristine, rough surface and local defects such as particles and cracks, E_On is limited to values around 100 MV/m or less. The present study suggests that laser polishing should be considered as an alternative to conventional polishing strategies of niobium accelerator cavities. Full article

Marble is widely used in the field of construction and home decoration because of its high strength, high hardness and good wear resistance. Diamond wire sawing has been applied in marble cutting in industry due to its features such as low material loss, high cutting accuracy and low noise. The sawing surface quality directly affects the subsequent processing efficiency and economic benefit of marble products. The surface quality is affected by multiple parameters such as process parameters and workpiece sizes, making it difficult to accurately predict through traditional empirical equations or linear models. To improve prediction accuracy, this paper proposes a prediction model based on backpropagation (BP) neural network. Firstly, through the experiments of sawing marbles with the diamond wire saw, the datasets of surface roughness and waviness under different process parameters were obtained. Secondly, a BP neural network model was established, and the mixed-strategy-improved whale optimization algorithm (IWOA) was used to optimize the initial weight and threshold of the network, and established the IWOA-BP neural network model. Finally, the performance of the model was verified by comparison with the traditional models. The results showed that the IWOA-BP neural network model demonstrated the optimal prediction performance in both the surface roughness Ra and waviness Wa. The minimum predicted values of the root mean square error (RMSE), mean absolute error (MAE), and mean absolute percentage error (MAPE) were 0.0342%, 0.0284% and 1.5614%, respectively, which proved that the model had higher prediction accuracy. This study provides experimental basis and technical support for the prediction of the surface quality of marble material cut by diamond wire saw. Full article

This paper proposes an improved wave function asperity elastic–plastic model. A cosine function that could better fit the geometric morphology was selected to construct the asperity, the elastic phase was controlled by the Hertz contact theory, the elastoplastic transition phase was corrected by the hyperbolic tangent function, and the fully plastic phase was improved by the projected area theory. The model broke through the limitations of the spherical assumption and was able to capture the stress concentration and plastic flow phenomena. The results show that the contact pressure in the elastic phase was 22% higher than that of the spherical shape, the plastic strain in the elastoplastic phase was 52% lower than that of the spherical shape, and the fully plastic phase reduced the contact area error by 20%. The improved hyperbolic tangent function eliminated the unphysical oscillation phenomenon in the elastoplastic phase and ensured the continuity and monotonicity of the contact variables, with an error of <5% from the finite element analysis. Meanwhile, extending the proposed model, we developed a rough surface contact model, and it was verified that the wavy asperity could better match the mechanical properties of the real rough surface and exhibited progressive stiffness reduction during the plastic flow process. The model in this paper can provide a theoretical basis for predicting stress distribution, plastic evolution, and multi-scale mechanical behavior in the connection interface. Full article

Fractures in marine sediments are critical zones for hydrate formation. The kinetics and morphological characteristics of hydrates within sandstone fractures are comprehensively investigated in this study by employing a high-pressure visualization reaction vessel to examine their formation, dissociation, and reformation processes. The results are presented below: (1) In 3 mm Type I fractures, the induction time is longer than that observed in the other two fracture widths. Hydrates predominantly form on the fracture walls and gradually expand toward both sides of the fracture. (2) Gas enters the fracture from multiple directions, causing the hydrate in Type X fractures to expand toward the center from all sides, which shortens the induction time and increases the quantity of hydrate formation. (3) An increase in fracture roughness promotes nucleation of the hydrate at surface protrusions but inhibits the total quantity of hydrate formation. (4) Hydrate dissociation typically propagates from the fracture wall into the interior, exhibiting a wavy surface morphology. Gas production is influenced by the fracture width, with the highest gas production observed in a 3 mm fracture. (5) Due to the memory effect, the hydrate induction time for reformation is significantly shorter, though the quantity of hydrate formed is lower than that of the first formation. This study aims to provide micro-level insights into the distribution of hydrates in sandstone fractures, thereby facilitating more efficient and safe extraction of hydrates from fractures. Full article

This study presents a systematic approach to engineering the electron transport layer (ETL) in perovskite solar cells using a spray deposition technique to fabricate sequentially compact and mesoporous titanium dioxide (c-TiO₂, m-TiO₂) films. The spray coating method leads to the development of a distinct reticulated morphology characterized by well-defined wavy-like surface features and significantly increased roughness—at least twice that of spin-coated mesoporous films. The increased interfacial area between the mesoporous TiO₂ and the perovskite layer facilitates more efficient charge transfer, contributing to higher device performance. By optimizing the deposition parameters, particularly the number of spray cycles for the m-TiO₂ layer, we achieve a significant enhancement in device performance, with improvements in power conversion efficiency (PCE), reduced series resistance, and minimized hysteresis. Our results demonstrate that an optimal film thickness promotes better perovskite anchoring, while excessive deposition impedes light transmission and increases sheet resistance. These findings advance the practical fabrication of high-performance perovskite solar cells using simple solution-processing techniques and highlights the potential of scalable spray deposition methods for industrial-scale fabrication. Full article