Gates ✉ the wetting of roughened surfaces is complicated since not all of the surface of the irregular surface is wetted and thus, the three-phase contact line for the liquid drop is a complex, three-dimensional line that varies according to the dimensions of the roughness and its spatial heterogeneity. this can cause the contact line to not sit within a constant height horizontal plane especially when air is trapped underneath the liquid layer. Here, we explore the effect of roughness on the effective contact angle of a water droplet on a roughened hydrophobic surface. the results show that the apparent contact angle varies around the periphery of the droplet due to the roughness of the surface on first contact. Also, repeated wetting of the droplet on the surface reveals that the apparent contact angle changes due to residual liquid remaining on the roughened surface. the results also show that the Wenzel and cassie-Baxter models tend to overestimate the apparent contact angle on the roughened surfaces.

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Residual stress is one of the most critical parameters in surface integrity, which has a great impact on fatigue life of the machined components. While the flank milling of titanium alloy Ti-6Al-4V has been widely applied to the manufacture of jet engine for its high productivity in aerospace industry, prediction of residual stress induced by this process is seldom reported. In this paper, an analytical model of residual stress is proposed, based on comprehensive analysis of the mechanical loading during flank milling. For the first time, the sequential discontinuous variable loading feature of flank milling is taken into consideration. An incremental elasto-plastic method followed by a relaxation procedure is used to get the stress-strain history of an arbitrary point in the subsurface so as to predict the residual stress retained in the workpiece after several loading cycles. We find that during the last phase in which the machined surface is generated, the main load comes from the plough effect of cutting edge as the uncut depth approaches zero. The simulation results indicate that the flank milled surface shows more compressive residual stress in the axial direction than in the feed direction. To validate the prediction, a series of cutting tests are conducted on Ti-6Al-4V using finish parameters and X-ray diffraction is utilized to obtain the residual stress.

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