Neste trabalho, medimos o perfil 3D de superfícies (microtopografia) utilizando uma técnica de interferometria óptica: Phase-Shi,ftzng (Deslocamento de Fase). Utilizamos um interferômetro do tipo Twyman-Green para produzir fi.guras de interferência da superfície analisada. Essas imagens foram armazenadas usando-se uma câmera CCD ligada à um microcomputador. Para obter a microtopografia, calculamos o Mapa de Fase a partir das imagens digitalizadas usando um programa de microcomputador. Posteriormente um outro programa removeu a ambiguidade da função tangente (unwrapping), pela Técnica do Autômato Celular, usada no cáiculo do Mapa de Fase. Então efetuamos os cálculos para determinar a microtopografia da superfície. Depois fizemos a análise da microtopografia, levantando informações relevantes para a sua caracterização. Analisamos objetos com alta refletividade (espelhos planos e redes de Ronchi) e obtivemos bons resultados. Também comparamos alguns dos resultados obtidos com a técnica de Deslocamento de Fase com os resultados obtidos pela análise de Franjas de Igual Espessura. / In this work we measured the 3D profile of surfaces (microtopography) using a optical interferometric technique: Phase-Shifting. We used a interferometer of type Twyman-Green to produce interferograms from analyzed surface. These images was captured using a CCD camera that was linked to a microcomputer. To obtain a microtopography, we calculated the Phase Map using the digitalized images and a software of microcomputer. Then another program removed the wrapping of tangent fuction, using the Cellular-Automata Technique, that was used to calculate the Phase Map. So we calculated the microtopography of the surface. After we did the analyses of the microtopography, find out some important informations of its description. We studied objects with high reflectivity (plane mirrors and Ronchi ruting) and we obtained good results. Also we compared some results with that obtained by analyses of Fringes of Equal Thickness\'

Variable data will play a decisive role in the future of packaging and product promotion. Variable data printing (VDP) is a technique whereby certain information can be altered in an otherwise static layout with the help of a digital printing system, and in the packaging industry a wide range of applications is possible. Inkjet printing, due to its non-impact printing (NIP) principle, is the most suitable technology to use when applying variable data on packaging and to offer customized and even personalized prints for the industry and the end-consumer (van Daele, 2005). The aim of the work described in this thesis was to evaluate the practicability of attaining high quality variable data print (VDP) at high speed. The thesis is divided into three major parts. Part one focussed on the surface topography of corrugated board and applicable analytical methods to describe the printability of the substrate. In the second part the performance of inkjet on corrugated board liners printed at high speed was investigated and how to achieve maximum printing resolution. The final part of the thesis is devoted to a market survey of variable data printing on the North American and European markets. Part 1 concentrated on corrugated board as substrate and its pre-conditions regarding surface topography before the printing operation. Most critical for the quality are print defects such as mottling, gloss and stripiness, all of which occur in the printing of corrugated board. Stripiness is especially critical because it is one of the most disturbing print defects on corrugated board since it is periodical and more easily perceived than random print defects (Netz, 1996). Part 1 revealed that there is a difference in surface micro-roughness between the regions on the peak line of the fluting and the regions in the valley between two peaks of the corrugation which leads to glossy lines on the peak areas. The aim of the second part was to assess the practicability of attaining high quality VDP at high speed on a variety of liners for corrugated board production. The trial was conducted on a Kodak Versamark DP5240 press in Örnsköldsvik, Sweden, in cooperation with the Mid-Sweden University - Digital Printing Centre (DPC). Nine different substrates were printed at speeds between 0.5 and 5 m/s. The results revealed that the paper type rather than the printing speed has the greatest influence on the print quality. Speed, however, is the most important technical factor for inline implementation of inkjet. To obtain a picture of the industries’ view of variable data print on fibre-based packaging, a market survey was initiated and was addressed to people in the development, marketing and decision-making sectors of the packaging and printing industry, including manufacturers of machinery, producers of packaging and prints, and print buyers. The goal was to draw an overview map covering the people’s view of their market, trends in their fields and how they envision the future of VDP on fibre-based packaging. The conclusion was that inkjet technology has to prove itself first and to increase its technical capability, and the printing industry will then start investing more in this technology and in applications such as VDP. / QC 20101206

Most of the surfaces have roughness down to atomic scales. When two surfaces come into contact, the nature of the roughness determines the properties like friction and wear. Analysis of the rough surface contacts is always complicated by the interaction between the material size effects and the micro-geometry. Contact mechanics could be simplified by decoupling these two effects by magnifying the scale of roughness profile. Also, tailoring the roughness at different scale could show a way to control the friction and wear through surface micro-structure modifications. In this work, the mechanics of contact between a rigid, hard sphere and a surface with a well defined roughness profile is studied through experiments and finite element simulation. The well defined roughness profile is made up of a regular array of pyramidal asperities. This choice of this geometry was mainly dictated by the fabrication processes. The specimens were made out of an aluminium alloy (6351-T6) such that there could be a direct application of the results in controlling the tribological properties during aluminium forming. Experiments on the pyramidal aluminium surface is carried out in a 250 kN Universal Testing Machine (INSTRON 8502 system) using a depth sensing indentation setup. A strain gauge based load cell is used to measure the force of the indentation and a LVDT (Linear Variable Differential Transformer) is used to measure the penetration depth. The load and the displacement were continuously recorded using a data acquisition system. A 3-D finite element framework for studying the elastic-plastic contact of the rough surfaces has been developed with the commercial package (ABAQUS). Systematic studies of indentation were carried out in order to validate the simulations with the experimental observations. The simulation of indentation of flat surface is carried out using the implicit/standard (Backward Euler) procedure, whereas, the explicit finite element method (Forward Euler) is used for simulating rough surface indentation. It is found that the load versus displacement curves obtained from experiments match well with the finite element results (except for the error involved in determining the initial contact point). At indentation depths higher than a value that is determined mainly by the asperity height, the load-displacement characteristics are similar to that pertaining to indentation of a flat, smooth surface. From the finite element results, it is found that at this point, the elastic-plastic boundary is more or less hemispherical as in the case of smooth surface indentation. For certain geometries, it is found that there could exist an elastic island in the sub-surface surrounded by plastically deformed material. This could have interesting applications.

Surface topography is, generally, composed of many length scales starting from its physical geometry, to its microscopic or atomic scales known by roughness. The spatial and geometrical evolution of the roughness topography of engineering surfaces avail comprehensive understanding, and interpretation of many physical and engineering problems such as friction, and wear mechanisms during the mechanical contact between adjoined surfaces. Obviously, the topography of rough surfaces is of random nature. It is composed of irregular hills/valleys being spatially correlated. The relation between their densities and their geometric properties are the fundamental topics that have been developed, in this research study, using the theory of random fields and the integral geometry.An appropriate random field model of a rough surface has been defined by the most significant parameters, whose changes influence the geometry of its excursion. The excursion sets were quantified by functions known as intrinsic volumes. These functions have many physical interpretations, in practice. It is possible by deriving their analytical formula to estimate the parameters of the random field model being applied on the surface, and for statistical analysis investigation of its excursion sets. These subjects have been essentially considered in this thesis. Firstly, the intrinsic volumes of the excursion sets of a class of mixture models defined by the linear combination of Gaussian and t random fields, then for the skew-t random fields are derived analytically. They have been compared and tested on surfaces generated by simulations. In the second stage, these random fields have been applied to real surfaces measured from the UHMWPE component, involved in application of total hip implant, before and after wear simulation process. The primary results showed that the skew-t random field is more adequate, and flexible for modelling the topographic roughness. Following these arguments, a statistical analysis approach, based on the skew-t random field, is then proposed. It aims at estimating, hierarchically, the significant levels including the real hills/valleys among the uncertain measurements. The evolution of the mean area of the hills/valleys and their levels enabled describing the functional behaviour of the UHMWPE surface over wear time, and indicating the predominant wear mechanisms.

Stable fixation of implants such as artificial teeth depends on the direct apposition of bone to the implanted material. While endosseous implants were traditionally allowed to "osseointegrate" over several months without carrying load, clinical and experimental data show that prostheses with roughened surfaces allow successful integration when subject to earlier loading and more challenging implant sites. However, to design implant surfaces for an optimal biological response requires an understanding of the mechanism by which roughened surfaces promote osseointegration. Research into this mechanism has, to date, focussed primarily on the response of osteoblastic cells to surface topography in vitro. While these have demonstrated some consistent trends in cell behaviour, the fundamental means by which cells sense and respond to roughness remain unclear. It has been suggested that cell responses to changes in topography may relate to differences in the proteins adsorbed from serum (in vitro). While experimental evidence indirectly suggests that physical features can affect protein adsorption, few studies have examined this with respect to surface roughness, particularly as a mediator of cell responses. To address this issue, cell culture and protein adsorption experiments were conducted on a limited range of surface textures. Titanium samples were ground to produce morphologically similar surfaces with three grades of roughness. A duplicate set of specimens were heated at 600°C for one hour, with the aim of masking potential variations in physicochemical properties with differing degrees of grinding. Osteoblast attachment and proliferation studies were conducted over a short time-frame of 48 hours or less, to highlight the effects of proteins adsorbed from serum rather than secreted by adherent cells. Gel electrophoresis provided a profile of the proteins adsorbed to each surface after 15 minutes, corresponding to the time by which the cells had settled onto the surface. Finally, confocal microscopy was used to examine cell morphology on each surface, and to visualize specific interactions between cellular structures and adsorbed adhesion-mediating proteins. Although the effects were inconsistent, attachment assays showed some indications that fewer cells attached in the first 90 minutes as roughness increased. This inverse cell number-roughness trend was significant at 48 hours; however, the variability in attachment assays prevented reliable separation of attachment and proliferation rate effects. While the reduction in cell number with increasing roughness is consistent with previous reports, it is typically observed at later time points, and thus may be increasingly confounded by contact inhibition and differentiation. Thermal oxidation of the titanium did not impact on osteoblast responses to roughness, although it significantly slowed cell proliferation. The latter result was unexpected on the basis of previous reports. One-dimensional gel electrophoresis revealed no significant differences in the composition of adsorbed layers with variations in roughness. However, as expected on account of wettability changes, the heat-treatment did correspond to significant changes in the adsorption profile. While this was not a highly sensitive analysis, it suggests that the cell responses to roughness changes were not governed by broadscale differences in the proteins initially available to adhering cells. In addition to the composition of the adsorbed layer, the distribution of proteins may also vary with topography. The immunofluorescence methods were not sufficiently sensitive to reveal the distribution of adsorbed adhesion proteins (vitronectin and fibronectin). However, the lack of clear labelling does suggest an absence of large accumulations due to specific topographic features. Further work is required to address this issue conclusively. Observations of cell morphology were consistent with widely-reported contact guidance phenomena on grooved surfaces, with elongation and alignment (with topography) increasing with groove depth. Cell elongation was also enhanced on the more hydrophilic, heat-treated titanium, but this effect diminished over time. Although increased elongation at 90 minutes corresponded to lower cell numbers at 48 hours, no causal relationship has yet been established.

Additive manufacturing is gaining popularity at a rapid rate and has been a resourceful production process to reduce material usage, wastage (scrap) and manufacturing costs for various applications. The project conducted, emphasizes on Thermoplastic Elastomer (TPE SE6300C-65A) material, which is a highly versatile compound, and has the ability to exhibit properties of both rubber (Elastomers) in terms of flexibility and plastic (Polymers) in terms of recyclability. Cost reduction without compromising quality is one of the important factors for industries. The project involves the use of TPE pellets to extrude filaments that could be used for 3D Printing. Filament extrusion involves process variables like Nozzle Temperature, De-humidification of pellets, Diameter of the nozzle, Distance of collection, Cooling and Angle of inclination of the extruder. These process variables are optimized to accomplish the desired quality of filament. The filament produced through extrusion is further used to make products using Fused Deposition Modeling (FDM). FDM also involves numerous process variables like Layer Thickness, Build Orientation, Print Infill, Print Speed etc. In this study, different test specimens, in terms of geometrical shapes are printed from the material, TPE SE6300C-65A and tested in order to understand how the surface features as well as the dimensional accuracy change with different process variables. It is observed that the surface topography produced throughout FDM process is majorly affected by the angle of orientation of the printed part. The main goal of this thesis is to give the reader a better understanding on which process variable, such as layer thickness, temperature and print speed affect the surface roughness of the models and also a comparison between these three variables, highlighting which is more or less affecting. It is also observed the dimensional accuracy of the real specimen deviate from the value input into the CAD software. The results obtained in this study clearly suggest that there is a lot of opportunities for future improvements especially regarding the dimensional accuracy, it is imperative to achieve the highest precision possible in order to have commercial values for the FDM 3D printing.

Neste trabalho, medimos o perfil 3D de superfícies (microtopografia) utilizando uma técnica de interferometria óptica: Phase-Shi,ftzng (Deslocamento de Fase). Utilizamos um interferômetro do tipo Twyman-Green para produzir fi.guras de interferência da superfície analisada. Essas imagens foram armazenadas usando-se uma câmera CCD ligada à um microcomputador. Para obter a microtopografia, calculamos o Mapa de Fase a partir das imagens digitalizadas usando um programa de microcomputador. Posteriormente um outro programa removeu a ambiguidade da função tangente (unwrapping), pela Técnica do Autômato Celular, usada no cáiculo do Mapa de Fase. Então efetuamos os cálculos para determinar a microtopografia da superfície. Depois fizemos a análise da microtopografia, levantando informações relevantes para a sua caracterização. Analisamos objetos com alta refletividade (espelhos planos e redes de Ronchi) e obtivemos bons resultados. Também comparamos alguns dos resultados obtidos com a técnica de Deslocamento de Fase com os resultados obtidos pela análise de Franjas de Igual Espessura. / In this work we measured the 3D profile of surfaces (microtopography) using a optical interferometric technique: Phase-Shifting. We used a interferometer of type Twyman-Green to produce interferograms from analyzed surface. These images was captured using a CCD camera that was linked to a microcomputer. To obtain a microtopography, we calculated the Phase Map using the digitalized images and a software of microcomputer. Then another program removed the wrapping of tangent fuction, using the Cellular-Automata Technique, that was used to calculate the Phase Map. So we calculated the microtopography of the surface. After we did the analyses of the microtopography, find out some important informations of its description. We studied objects with high reflectivity (plane mirrors and Ronchi ruting) and we obtained good results. Also we compared some results with that obtained by analyses of Fringes of Equal Thickness\'

O processo de estampagem é influenciado por diferentes variáveis, tais como, propriedades mecânicas e rugosidade da chapa, lubrificação do blank, coeficiente de atrito entre o blank e a ferramenta, parâmetros da prensa (força relativamente constante e velocidade), bem como variações nas ferramentas de conformação (deformação elástica). Este trabalho se dedica a investigação da influência do atrito entre a ferramenta e o blank. Em particular, será investigado o desenvolvimento de padrões artificiais de rugosidade de chapas metálicas (textura de superfície). O foco do presente trabalho é o estudo, em condições industriais, da inter-relação entre topografia superficial caracterizada pelos parâmetros de rugosidade 2D e 3D e estampabilidade de chapas de aço para painéis automotivos. Diferentes texturas superficiais de chapas de aço foram analisadas em termos de estampabilidade (medido pelo deslocamento do blank durante a estampagem) e tentativamente relacionadas com os parâmetros de rugosidades (2D e 3D) obtidos na chapa antes de estampar. Algumas tendências relevantes foram estabelecidas entre estes parâmetros. Os resultados aqui apresentados estão em concordância com publicações recentes mostrando uma clara relação entre estes parâmetros e que trabalhos futuros são necessários. / The stamping process is influenced by several variables such as sheet mechanical properties and roughness, blank lubrication, friction coefficient, press parameters (press force and speed), as well as variations in the forming tools (elastic strain). This work is dedicated to study the influence of friction between the tool and the blank. In this sense, it is necessary to study the development of artificial roughness patterns of sheet metals (surface textures). The aim of this research work is to study the inter-relationship, using the surface topography characterized by 2D and 3D roughness parameters and the formability of steel sheets for automotive panels. Different surface textures of sheet metal have been evaluated in terms of formability (measured by material flow during the process stamping) and tentatively related to roughness parameters (2D and 3D) obtained in the sheet metal prior to stamping. Some relevant tendencies have been established amongst these parameters. The results presented here are in accordance with other recently published research work showing that there is a clear relationship between these parameters, and that further detailed studies are needed.

The aim of this research work is to study the inter-relationship, under controlled industrial conditions, among skin pass reductions, surface topography characterized by 2D and 3D roughness parameters, stampability and painted surface finish quality for automotive steel sheet stampings. Different surface textures obtained from cold rolling finishing have been evaluated in terms of paint appearance (rating and spectral curve) and tentatively related to roughness parameters (2D and 3D) obtained from the cold finished sheets. Some relevant tendencies have been established amongst these parameters. The results presented here are in accordance with other recently published research showing that there is a clear relationship between these parameters, and that further detailed studies are needed. / O foco do presente trabalho é o estudo, em condições industriais, da inter-relação entre grau de redução do passe de acabamento, topografia superficial caracterizada pelos parâmetros de rugosidade 2D e 3D, estampabilidade e aparência de pintura de chapas de aço para painéis automotivos. Diferentes texturas superficiais de chapas de aço foram analisadas em termos de aparência de pintura (rating e curvas espectrais) e tentativamente relacionadas com os parâmetros de rugosidades (2D e 3D) obtidos na chapa antes de estampar. Algumas tendências relevantes foram estabelecidas entre estes parâmetros. Os resultados presentes aqui estão de acordo com publicações recentes mostrando uma clara relação entre estes parâmetros e que trabalhos futuros ainda são necessários.

In recent years, multi-jet fusion technology became more popular as it has unlimited potential. Thanks to this technology, it became possible to produce products with complex geometries.This gives a massive advantage compared to the conventional manufacturing process, as by utilising 3D printers, the costs and environmental impact are reduced exponentially with regards to the fact that this is a new technology. Product quality is one of the most important factors when it comes to product manufacturing for a company to stay competitive in the market. This study was conducted in FABLAB at Halmstad University. The research focuses on different aspects of the fabricated test artefacts, such as surface roughness, tensile strength and dimensional deviation. How different printing parameters can affect the printing quality of the printed parts is then analysed. The result is then compared with designed CAD model. During this study, some experiments were conducted by printing test samples at different build orientations to define the printing quality. Measurement is conducted on the different test artefacts and quantified. The effect from build orientation on surface roughness, tensile strength and dimension accuracy were studied during this thesis. The test samples were measured by using appropriate measuring equipment that was available at Halmstad University. From the test results, it becomes clear that the build orientation directly impacts the printing quality of the printed test samples from the HP multi-jet fusion 3D printer