Analysis of Surface Texture and Roughness in Composites Stiffening Ribs Formed by SPIF Process

Abstract

Studying roughness parameters and the topography of stiffening ribs in composite sandwich structures is important for understanding these materials’ surface quality and mechanical properties. The roughness parameters describe the micro-geometry of the surface, including the average height deviation, roughness depth, and waviness. The topography of the surface refers to the spatial arrangement and distribution of features such as bumps, ridges, and valleys. The study investigated the roughness parameters under three scenarios based on two SPIF process parameters: tool rotational speed(N) and feed rate (f). The vertical step was held constant at 0.4 mm across all scenarios. In scenario A, the process parameters were set at f = 300 mm/min and n = 300 rpm; in scenario B, f = 1500 mm/min and n = 3000 rpm; and in scenario C, f = 1500 mm/min and n = 300 rpm. The experimental research topography analyses revealed that the surface roughness of the stiffened ribs was highly dependent on the SPIF process parameters. The highest feed rate and tool rotational speed produced the smoothest surface texture with the lowest maximum height (Sz) value. In contrast, the lowest feed rate and tool rotational speed resulted in a rougher surface texture with a higher maximum height (Sz) value. Furthermore, the contour plots generated from the topography analyses provided a good visual representation of the surface texture and roughness, allowing for a more comprehensive analysis of the SPIF process parameters. This study emphasizes optimizing the SPIF process parameters to achieve the desired surface quality and texture of stiffened ribs formed in Litecor® panel sheets.

Experimental Investigation of Load-Bearing Capacity in EN AW-2024-T3 Aluminum Alloy Sheets Strengthened by SPIF-Fabricated Stiffening Rib

“…Additional studies analyzing the LITECOR ® composite panels were later introduced. Raheem Al-Sabur et al [20] analyzed the roughness and effects on the surface texture of SPIF-strengthened LITECOR ® composite panels. Their study investigated the influences of tool rotational speed and feed rate, revealing that the highest feed rate and tool rotational speed resulted in the smoothest surface texture with the lowest maximum height value.…”

Influence of Innovative Post-Weld Finishing Method on Bead Surface Quality

“…In order to conduct a study on the innovative post-weld finishing effect in steel specimens produced using different welding methods and its impact on the key surface quality parameters, the 2D and 3D surface roughness measurements were performed [ 13 , 14 , 15 , 16 , 17 ]. The level of selected surface roughness parameters determined its functional properties: fatigue strength, wear and corrosion resistance, contact strength, tribological properties, adhesion, and others.…”