Monday 27 May
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"Monday 27 May"

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POSTER SESSION

00:00 - 00:00 #39974 - Surface topography assessment of the wax patterns produced by material jetting technology for investment casting.
Surface topography assessment of the wax patterns produced by material jetting technology for investment casting.

Investment casting, a widely employed manufacturing process in the production of intricate metal components, relies heavily on the quality and precision of the initial wax patterns [1]. The growing adoption of Material Jetting Technology (MJT), a type of Additive Manufacturing (AM) [2], for crafting these wax patterns necessitates a comprehensive understanding of the resulting surface characteristics. The investigation begins with an in-depth exploration of the MJT process, emphasizing its relevance in creating intricate and complex geometries typical of investment casting wax patterns (see Fig. 1a). The focus is to identify the influence of key process parameters on the surface finish of the printed wax patterns [3]. The material jetting method allows for the layer-by-layer deposition of wax material, and a detailed analysis is conducted to assess the impact of layer thickness, print resolution, build orientation, and geometrical design on the final properties of the wax patterns [4]. Subsequently, the study transitions to the Investment casting phase, scrutinizing the translated qualities of the 3D-printed wax patterns into the casted metal components. Figure 2 displays the casted metal components using the 3Dialog CeraCaster® MJT machine and the Investment casting process. Emphasis is placed on evaluating the fidelity of the casted parts to the original design and investigating any deviations in surface finish introduced during the casting process. Factors such as mold quality, casting temperature, and cooling rates are analyzed for their influence on the outcome.[5] Characterization technique to conduct the assessment, including interferometry for surface roughness analysis (see Fig. 1b). The study aims not only to quantify the surface finish but also to identify correlations between the MJT process parameters, wax pattern qualities, and the subsequent casting results. The findings of this research are anticipated to provide valuable guidelines for practitioners in various fields such as dentistry, jewelry, automotive, aerospace applications, and so on, providing the tool for optimization of MJT parameters for enhanced surface finish in wax patterns intended for Investment Casting. Moreover, the study contributes to the field of hybrid manufacturing, involving the integration of AM technologies and traditional casting processes, fostering advancements in the production of high-quality metal components.
Amogh Vedantha KRISHNA, Tim MALMGREN, Vijeth Venkataram REDDY, Paulo KIEFE, Stellan BRIMALM, Bengt-Göran ROSÉN (Halmstad, Sweden)
00:00 - 00:00 #40124 - A Tribocorrosion Investigation in Food Industry Cleaning Processes.
A Tribocorrosion Investigation in Food Industry Cleaning Processes.

The objective of the presented research is to investigate the relationship between the concept of electrochemical lubrication and the mechanisms of passive film formation encountered during the cleaning process in the food industry. Experimental campaigns were conducted on various types of stainless steels (316L/316L, 316L/uranus45, 316L/Nitronic60, 316L/304, 316L/carbon steel) using a tribometer coupled with a potentiostat in a basic environment. Wear tracks resulting from tribocorrosion experiments were examined using various microscopic and spectroscopic characterization techniques such as SEM, AFM, Raman spectroscopy, XPS, and ToF-SIMS. The electrochemical results, obtained by measuring the open circuit potential, align seamlessly with tribological findings. Specifically, the stability of the friction coefficient is proportional to the potential, and the reduction in the friction coefficient is inversely proportional to the potential. Physico-chemical analysis revealed the morphology and chemical composition of the passive film formed on the surface based on the type of steel under investigation. These findings serve as a foundation to deepen the fundamental understanding of the electrochemical lubrication phenomenon in stainless steels exposed to a basic environment. Tribocorrosion tests aim to replicate industrial cleaning conditions, with the goal of reducing energy consumption related to frictional components and increasing equipment lifespan.
Kaouthar BOUGUERRA (TOURS), Caroline RICHARD, Yan-Ming CHEN, Nadège DUCOMMUN, Pierre-Francois. CAREDY, Alexandre ROMAINE
00:00 - 00:00 #40728 - AI-driven proactive quality control: predictive modelling for surface roughness in milling.
AI-driven proactive quality control: predictive modelling for surface roughness in milling.

The manufacturing sector constitutes approximately 20% of the GDP [1], encompassing a specialized segment known as precision manufacturing. This sector focuses on exacting tolerances in geometry, dimensions, and surface roughness. Among the quality criteria crucial for precision manufacturing is the control of surface roughness in machined parts, traditionally performed outside machine tools [2]. In the context of evolving sustainability standards, the precision manufacturing industry faces the necessity of adapting to new guidelines. Scrapping, the disposal of parts failing to meet quality criteria within the industrial environment, presents a significant challenge. Scrapped parts, deemed substandard, are discarded, resulting in material wastage. This work aims to develop a proactive quality control method with the ultimate objective of correcting machining cutting parameters (e.g., spindle speed, cutting depth, feed rate) in a continuous way during the cutting process. The aim is to prevent the production of parts with out-of-tolerance surface roughness. This approach aligns with the concept of Zero-Defect Manufacturing (ZDF), reflecting a commitment to achieving impeccable quality and minimizing wastage in the precision manufacturing industry. For that, three different non-contact surface roughness sensors from industrial partner STIL/Marposs were implemented on- machine (Fig. 1a) and tested on roughness physical standards to determine the most suitable sensor for the purpose of this work (Fig. 1c). Then, a large batch of surface milling experiments was performed on aluminium (Fig. 1b) to generate a robust database for the AI-modelling investigation. In total, 125 combinations of cutting conditions were applied, and for each machined surface, 6 profiles were measured. With a 3-axis dynamometer, the cutting forces were also acquired during the cutting experiments. By combining data of the input machining parameters, cutting forces, and resulting surface roughness parameters, a database was created. From that, different AI models were constructed with distinct architectures and performances, allowing the assessment of each algorithm's predictive accuracy. The prediction of surface roughness was investigated using two different architectures: Neural Networks (NN) and ensemble methods.
Ricardo KNOBLAUCH (Aix-en-Provence)
00:00 - 00:00 #38854 - Compensation of geometrical errors during application of a confocal sensor system to analyse aerospace structures.
Compensation of geometrical errors during application of a confocal sensor system to analyse aerospace structures.

A non-contact system based on a confocal chromatic sensor was developed to measure the actual geometry after individual machining steps in the machining of components for the aerospace industry, allowing the actual geometry to be compared with the target geometry even in deep cavities of the structure with aspect ratios greater than 20. This technology is necessary in order to apply not only sophisticated machining strategies but also specific monitoring of the machining quality for the precision requirements of components in the aerospace sector. The result of the geometric nominal/actual comparison is the basis for CAM planning of the subsequent machining steps. By coupling the sensor system to a machine tool via standard interfaces (HSK) and carrying out measuring cycles based on modified NC programmes, data can be recorded via a control-connected IoT gateway (EDGE system). In addition to the design of the measuring system and its integration into the machine's ecosystem, a concept for calibrating the measuring system for operation on the machine tool was developed [1]. This is based on pyramidal or conical reference elements (Figure 1). Various aspects of the calibration approach were analysed using a simulation model of the measuring system. As a result, inclination errors and axis deviations of the measuring system can be identified and corrected in the measuring system on the hardware side as well as taken into account on the software side.
Uwe TEICHER (Dresden, Germany)
00:00 - 00:00 #38809 - Effect of the substrate pre-heating temperature on the microstructure and wear behaviour of laser powder bed fusion additive manufactured H13 steel.
Effect of the substrate pre-heating temperature on the microstructure and wear behaviour of laser powder bed fusion additive manufactured H13 steel.

In the process of laser additive manufactured steels, the elevated preheating temperature of the substrate can effectively reduce the temperature gradient, thereby achieving the goal of minimizing residual stress and suppressing the generation of cracks. However, the increment of the preheating temperature typically induces significant changes in the microstructure and mechanical properties. This study delves into the investigation of the microstructure and wear behaviour of laser powder bed fusion (LPBF)processed H13 steel, subjected to preheating temperatures of 200℃ and 500℃, which is considered as one important hot work tool steel with nonnegligible cold cracking tendency during laser processing. Then, the wear behaviour was studied using a reciprocating ball-on-plate tribometer, sliding against the 100Cr6 steel ball at room temperature under various loads (10N, 30N, 50N). The results show that as the preheating temperature increased from 200℃ to 500℃, the volume fraction of retained austenite decreased with improvement in microhardness and wear resistance. Moreover, for the LPBF-processed H13 steel with 200℃ and 500℃ preheating, the coefficient of friction exhibited a continuous decrease with an increase in applied load, while the wear rate initially increased and then decreased. Although there is a similar trend in wear rate and coefficient of friction with changing applied load, the distinct wear mechanisms were observed. For the LPBF-processed H13 steel with 200℃ preheating, under a 10N load, the primary wear mechanisms were adhesive and abrasive wear due to the relatively small tribo-oxide patch formed. As the applied load increased to 30N, the tribo-oxide layer coverage increased, simultaneously, the tribo-oxide layer underwent rupture, resulting in oxidative wear. When the applied load increases to 50N, the density of the tribo-oxide layer increased. After the tribo-oxide layer spalled off, a new oxide film regenerated on the exposed the substrate material, resulting in mid-oxidative wear. The LPBF-processed H13 steel with 500℃ preheating could form a relatively dense tribo-oxide layer to protect the substrate even under a 10N load, which means it exhibited superior oxidizability compared to the sample with 200℃ preheating. The predominant wear mechanisms were mid-oxidative wear and abrasive wear. With an applied load increase to 30N, the formation of the tribo-oxide layer was similar to the situation observed in sample with 200℃ preheating under a load of 50N. When the applied load increased to 50N, the tribo-oxide layer was grounded into oxide particles while undergoing delamination. However, it should be noted that the plastic deformation and strain hardening in the subface region occurred, which could hinder the crack propagation and ensure the outstanding wear performance. Therefore, the higher oxidizability, hardness, and work hardening of LPBF-processed H13 steel wit 500℃ preheating contribute to its superior wear resistance.
Huajing ZONG (chalons-en-champagne), Nan KANG, Zehao QIN, Mohamed EL MANSORI
00:00 - 00:00 #39878 - Effects of Resolution on Finite Element Analysis for Two-Dimensional Rough Surfaces Contact.
Effects of Resolution on Finite Element Analysis for Two-Dimensional Rough Surfaces Contact.

The contact problem of structured surfaces with strong anisotropic properties is attracting increasing attention in the field of modern manufacturing industries. A preferable precise evaluation method accounts the contribution of asperities across the multiscale from nanometres to milometers. However, limited by computing efficiency, a full-dimensional scale finite element simulation on the contact of surfaces is not practical yet. The most common practice is to represent the surface with discrete height maps to calculate the contact behaviour with finite element method (FEM). However, this approach raises the issue that the evaluation results are sensitive to discrete resolution. Currently, quantitative examination is required to determine the adequate lateral resolution of the surface topography represented in finite element meshes. In this paper, the effects of different lateral resolutions on the contact response are investigated on a series of deterministically generated surfaces. A parental surface with ultra-fine spatial resolution is generated by the random process model. Then a set of derivative surfaces are obtained by resampling the parental surface. These surfaces are similar both in height magnification and phase. Compared with fully random surface generation methods, our method possesses the capability to perform a deterministic rough surface contact analysis meanwhile preserving the same power spectral density (PSD) as the original surface, which is crucial for the comparison of the contact response. In this paper, the contact problem of a rough surface compressed by a rigid flat plane is studied using FEM. The simulation results indicate that the averaged pressure increases as the lateral resolution of the deterministic rough surface increases until it converges to a nearly constant value. Thus, a critical lateral resolution applicable to the evolution of rough surface contact is determined when the averaged pressure reaches the constant value. An explicit expression of the pressure-resolution relation is obtained by fitting the simulation results, a case study with a milled surface from NIST database is examined to validate the effectiveness of the expression. The study provides a solution to quantify the 'sufficient fine resolution' of surface topography in finite element simulation for tribological performance evaluation. This will improve the efficiency and accuracy of functionality assessment of engineering surfaces under contact conditions.
Sihe WANG (Xi'an, China), Xuanming LIANG, Weike YUAN, Wenbin ZHONG, Wenhan ZENG, Jiang XIANGQIAN, Gangfeng WANG
00:00 - 00:00 #40059 - Error analysis and compensate method for beam splitter based hybrid structured-light metrology system.
Error analysis and compensate method for beam splitter based hybrid structured-light metrology system.

Hybrid structured-light metrology technique is studied for form measurement of structured surfaces with both reflective and diffuse characters, whose system consists of a fringe projection profilometry (FPP) system and a phase measuring deflectometry (PMD) system. Beam splitter (BS) based compact configuration has been proposed to reduce the system volume of a hybrid structured-light metrology system for improving the portable and in-line measurement ability of the hybrid measurement system, but the using of the BS also introduces error. When conducting measurement with the FPP system, the optical fields of the camera and the projector are required to be overlapped on the sample under test (SUT). At the same time, the light of the camera and the projector will be reflected by the BS and projected onto the system bottom surface. The captured deformed fringe patterns by the camera contain not only the SUT’s form information but also the system bottom surface’s information, which leads to a large measurement error. In this paper, methods are studied to eliminate the BS’ impact on FPP measurement accuracy in a hybrid structured-light metrology system. Influence of the BS is analysed and discussed through imaging model study. Different compensate methods based on the analysis are tested and compared through experiments. A black stage-based technique is developed for a hybrid structured-light metrology system to remove the BS’s affection on measurement accuracy. The camera and projector light reflected by the BS will be blocked by the black stage to reach the system bottom. A portable hybrid structured-light metrology prototype with the BS configuration is developed based on the proposed compensate technique. Experiments have been conducted and verified the effectiveness of the proposed compensate technique by measuring structured composite samples. An in-line measurement experiment using the developed hybrid structured-light metrology prototype illustrates that the proposed techniques can achieve 24.8 µm form accuracy in a form measurement of rough surfaces and 400 nm form accuracy in a form measurement of specular surfaces.
Yongjia XU (Huddersfield, United Kingdom), Feng GAO, Yanling LI, Xiangqian JIANG
00:00 - 00:00 #38808 - Fatigue Behavior of Laser Powder Bed Fusion H13 Tool Steel: Effects of Preheating Temperature and Surface Roughness.
Fatigue Behavior of Laser Powder Bed Fusion H13 Tool Steel: Effects of Preheating Temperature and Surface Roughness.

Laser additive manufacturing (LAM) techniques are widely employed for producing metal components with complex geometries. However, the internal and external surfaces of these components are often challenging to post-machine process. The defects on these surfaces significantly influence the fatigue behavior of the components, necessitating detailed research to discern appropriate processing conditions and performance levels. This study investigates the impact of surface roughness on the mechanical properties and low-cycle fatigue behavior of H13 tool steel manufactured using laser-powder bed fusion (L-PBF) additive manufacturing at different preheating temperatures. Both quasi-static tests and uniaxial tensile-compression fatigue tests were conducted on L-PBF H13 tool steel specimens manufactured vertically (deposition direction parallel to the loading axis) at preheating temperatures of 200°C and 500°C, both in as-built surface conditions and machined to remove the surface conditions. Two non-destructive characterization techniques (micro-CT and interferometer) were employed to determine the relationship between surface contour parameters and surface roughness. The influence of surface roughness on fatigue performance was found to be more significant than the effect of preheating temperature, noticeably reducing the fatigue performance of the components. Surface defects prompted the initiation of fatigue cracks, manifesting as multiple locations of fatigue crack initiation on the surface of the as-built samples. In contrast, machined samples exhibited fatigue cracks originating from only one location. This underscores the decisive role of surface roughness in the fatigue fracture behavior of components. Additionally, specimens deposited at 500°C demonstrated higher fatigue performance compared to those at 200°C, even with the same surface contour. The increased preheating temperature largely released internal residual stresses in the components and transformed the material's microstructure, thus extending the initiation and propagation cycles of fatigue cracks. This work establishes the processing-structure-performance (PSP) relationships of components under different processing conditions, aiming to guide future process parameter optimization and provide insights for the identification strategy of additive manufactured components.
Qin ZEHAO (chalons-en-champagne), Nan KANG, Zong HUAJING, Mohamed EL MANSORI
00:00 - 00:00 #39999 - Functional surface analysis in mechanical engineering.
Functional surface analysis in mechanical engineering.

Improving the quality of manufacturing processes for machine and equipment parts is directly related to with the improvement of inspection methods for manufactured products. This is related to the simultaneous development of the quality control department and the use of increasingly advanced and accurate measuring equipment. One of the most important parameters determining the quality of the product is the structure of the manufactured parts, determined by the type of processing and manufacturing method. An important issue of assessing the condition of the structure is the widely understood surface roughness, which is one of the basic parameters determining the quality of manufactured parts also affecting the functional properties, functional properties, durability or interchangeability of parts in mechanical engineering. Analysis of the literature has shown an increase in interest in issues related to the accuracy and reliability of surface topography measurement. Currently, the most widespread and reliable methods for profile measurements are contact methods, in which the measurement of surface irregularities is carried out using a diamond measuring tip with an opening angle of 60° or 90° and a rounding radius of 2 to 10 m moving over the surface under test at a constant speed over the measuring distance. These are well-established methods, but they are also sensitive to interference factors, including vibration, thermal effects or geometric errors of the measuring tip. Modern quality control requires the use of devices that will return information about the measurement of a selected quantity in a possibly correct manner while maintaining the required accuracy. When the measurement is carried out with standard measuring equipment, solutions are sought to eliminate the influence of interfering factors in an autonomous manner after the basic measurement. Often methods of extensive filtration are used. Surface roughness measurements are classified among the most complex and complicated. Knowing the essence of the surface condition is extremely important from the point of view of machine operation and the durability of mating parts. Taking into account the parameters determining the surface condition, it is possible to influence wear processes, corrosion resistance or fatigue strength. There are also non-contact (optical) techniques for measuring surface roughness. Optical methods use a beam of light reflected from the surface under study for analysis. The light incident on the surface can be white light or light of a certain wavelength or laser light. Optical techniques for measuring surface irregularities use a variety of methods for mapping the structure under study. Often measurements are carried out using several methods implemented in a single device. Each of the listed independent methods, contact or non-contact, carries advantages as well as disadvantages. Combining the advantages of each technique makes it possible to learn about the surface structure in the most correct way. The main objective of the Polish Metrology project entitled: "Functional Analysis of Surfaces in Mechanical Engineering" is the analysis of surface texture, using methods for the extraction and identification of its characteristics that determine their functionality, and the development of measurement methodology in the context of their future operation. Materials with a wide range of applications will be tested, both in terms of utility (wear resistance, hardness or applicability in the food industry) and functional characteristics of the geometric structure of the surface.
Karol GROCHALSKI (Poznań, Poland), Michał WIECZOROWSKI
00:00 - 00:00 #38839 - Implementation of a traceability chain for areal surface texture parameters using a metrological large range AFM.
Implementation of a traceability chain for areal surface texture parameters using a metrological large range AFM.

The ISO standardization framework in the field of calibration, adjustment and performance specification has recently been published. It contains of three different pillars: the metrological characteristics that feature a direct contribution to the measurement uncertainty [1], and are the properties that are subject to a calibration, the corresponding material measures whose geometries can be used to map these characteristics [2] and the calibration routines that are described in the recently published standard ISO 25178-700 [3]. The comprehensive calibration in this context describes the determination of the basic metrological characteristics. The processes associated with the areal traceability and uncertainty propagation however still lack of experience even though a first framework to derive the measurement uncertainty based on the measurement results of the metrological characteristics has been proposed by Leach et al. [4]. Especially the practical implementation of traceability chains containing multiple calibration processes based on the areal surface texture parameters is still subject of research. We describe a case study for the implementation of a traceability chain, using a high-speed metrological large range AFM [5] to measure an additively manufactured type AIR material measure as defined in ISO 25178-70. The material measure is based on a practical engineering surface, features defined values of Sa and Sq and is manufactured using a two-photon polymerization. Starting from the traceability chain of the AFM, the material measure is calibrated and subsequently used to calibrate an optical surface topography measuring instrument which in a case study is chosen as a confocal microscope. The processes of the traceability chain just as well as the determination of the confidence interval of the areal surface texture parameters is described and the industrial application for the calibration of optical surface topography measuring instruments using the areal surface texture parameters is outlined. The suggested calibration routine is easy to implement in practice and allows an efficient uncertainty estimation of the acquisition of areal surface texture parameters.
Matthias EIFLER (Erfurt, Germany), Gaoliang DAI, Julian HERING-STRATEMEIER, Georg VON FREYMANN, Jörg SEEWIG
00:00 - 00:00 #40812 - Preserving Van Gogh's Painterly Heritage: Topographical and Fractal Insights in Authentication.
Preserving Van Gogh's Painterly Heritage: Topographical and Fractal Insights in Authentication.

The search for topographic signatures in an artist's body of work represents an innovative and sophisticated approach, utilizing fractal analysis [1]. This method aims to provide additional indicators to art experts, based on the idea that each artist develops distinctive traits in their painting style, identifiable through unique topographic features. Topographic signatures, in this context, encompass patterns, textures, color choices, brushstrokes, and other specific visual elements that recur in the works of a given artist [2]. By employing fractal analysis, this method explores the complex, self-similar structures present in these features, providing an in-depth understanding of artistic patterns on a detailed scale. Fractal analysis, as a tool, allows for a finer detection of subtle patterns, sometimes escaping the human eye, by assessing geometric similarity at different scales. Algorithms apply this approach to datasets comprising authenticated works by the specific artist, as well as those of other contemporary artists, training the computer model to recognize specific topographic signatures. The objective of this research, reinforced by fractal analysis, is to enhance the artistic attribution process by providing experts with more advanced tools to assess the authenticity of a work of art. By integrating fractal analysis, this method offers a more in-depth approach to exploring artistic features, contributing to a better understanding of an artist's style over time and a more precise validation of the attribution of artworks. In this study, we use a list of paintings unquestionably attributed to Van Gogh to construct our statistical model based on fractal dimension. Once this model is sufficiently robust, we compare it with works by the artist that have been the subject of controversy, such as "Sunset at Montmajour," which was thought to be a forgery for years, and "The Labourers," (Figure 1) which is a proven forgery but has nonetheless cast doubt on the art market.[3,4] To ensure the robustness of the model, we calculated the fractal dimension from different areas, starting with the scale of a brushstroke, then a pattern, and finally over the entire topography.
François BERKMANS (Poznan / Poland)
00:00 - 00:00 #40029 - Surface topography of casting patterns produced using selected additives technologies after the molding process.
Surface topography of casting patterns produced using selected additives technologies after the molding process.

Additive manufacturing technologies especially 3D printing technologies can be used to produce prototypes and functional machine parts [1,2]. Additive technologies can also be used in foundry, e.g., to produce casting patterns or foundry molds [3]. It should be noted that traditional methods of making foundry patterns are time-consuming and have a negative impact on the natural environment. Moreover, the application of 3D printers allows for "immediate" printing of the final part, which significantly improves the procedure of production of casting patterns [4]. The main purpose of the research presented in the paper is to assess the impact of the molding process affect at the surface topography of casting patterns produced using three different types of additive technology, namely: Fused Deposition Modeling (FDM), PolyJet Matrix (PJM) and Selective Laser Sintering (SLS). Casting patterns in the PJM technology were made of FullCure 720 liquid polymer resin, using a thickness of a single layer of material Lt=0.016mm. In the FDM technology, ABS P430 building material and parameter Lt=0.254mm have been used. PA2200 polyamide powder was used to produce samples in SLS technology. The thickness of a single layer of the printing material was Lt=0.1mm and laser energy density was applied: ED = 0.08 J/mm2. Samples for all analyzed technologies were printed using a printing direction equal Pd=0˚. The surface topography was measured with the Talysurf CCI measuring system based on coherence correlation interferometry technology. A measuring objective with X20 magnification was used and surfaces measuring 0.84mm x 0.84mm were analysed. The assessment of the change in the surface topography of casting patterns made using additive technologies was performed quantitatively. The change in the values of surface topography parameters was examined i.e. Sa, Sz and Sq. Analysing the measurement results, it can be seen that the lowest values of the Sa and Sz parameters were obtained for the surfaces of casting patterns produced using the PolyJet Matrix technology. However, the highest values for the tested parameters were obtained for the Selective Laser Sintering technology. Significant disproportions are visible surface topography parameters measured for surfaces printed using various types of additive technologies. For example, the value of the Sa parameter is over nine times higher for models made with SLS technology than for the same models made with PJM technology. Moreover, by analysing the change of the values of Sa parameter as a result of the molding process, it can be concluded that for all the examined additive technologies there was a decrease of the value of the tested parameter. A similar tendency was noted for the Sz parameter, excluding the PJM technology, where a slight increase in the Sz parameter value was observed. However, investigating the value of the Ssk (skewness) parameter, it can be stated that expect the FDM technology for the primary models, positive values of the Ssk parameter were noted, which indicates the surfaces with many single peaks. It should be stated that the molding process for all analysed samples resulted in a reduction of the Ssk parameter. For casting patterns manufactured using FDM and SLS technology, after 100 molding cycles, a surface similar to a plateau can be noted. This indicates some surface wear due to the molding process. However, it can concluded that the surface made using PJM technology is more resistant to wear.
Paweł ZMARZŁY (Kielce, Poland), Tomasz KOZIOR, Damian GOGOLEWSKI
00:00 - 00:00 #40017 - The use of computer microtomography in surface measurements of elements produced by the additive technology MJF.
The use of computer microtomography in surface measurements of elements produced by the additive technology MJF.

MJF, or Multi Jet Fusion, is a state-of-the-art 3D printing technology utilizing powdered plastics for additive manufacturing. This process involves uniformly heating the powdered bed, leading to a sintering phenomenon, allowing for the production of 3D objects. Surface geometry is pivotal for physical objects, influencing their intended purpose. The geometric structure of a surface impacts various physical conditions, such as mechanical strength, coating adhesion, and bacterial distribution. Traditional contact or optical methods were historically sufficient for surface measurement. However, with the advent of additive techniques, limitations surfaced. Real surface profiles deviated from classical functions, introducing the concept of "re-entrants," where a surface profile takes more than one ordinate for a given abscissa. Measuring such surfaces became challenging, especially as contact or optical methods failed to provide information about about non-visible or non-reachable portions of the surface. MJF technology exacerbates this challenge, as it necessitates the removal of powder formulated during printing, leading to the formation of re-entrants covered by powder. Traditional cleaning methods, like sandblasting, may damage and alter the machined surface's geometric character. To address these issues, the proposal suggests using computer microtomography (µCT) for surface data acquisition and evaluation. This measurement method, utilizing X-ray radiation and image reconstruction, offers the unique ability to observe hidden geometric features inaccessible to other devices. µCT's application in evaluating surfaces produced by MJF technology serves a dual purpose. Firstly, it provides information about the surface beneath the remaining powder, a feature unique to this technology. However, post-processing, such as powder removal, introduces surface deformations, necessitating an assessment of how the surface geometry changes. The second aspect involves addressing the re-entrant nature of the surface, posing challenges for reliable measurement with conventional methods. These methods often overlook information about structures hidden by the surface's own geometry. To understand surface changes, samples created with MJF technology were measured before and after post-processing using µCT. The obtained results were compared, offering insights into surface geometry alterations. For comprehensive surface validation and control, a proprietary algorithm was introduced to determine the presence of potential re-entrants. After exporting the surface from µCT measurements and implementing it into the algorithm, the analysis revealed the occurrence and distribution of re-entrants on the surface. This approach aids in deciding whether a specific surface should be measured using µCT or traditional methods. An exemplary result, illustrated in Figure 2, showcases the ratio of the area of individual triangles projected onto the nominal plane to the area of the projection of the entire surface onto the nominal plane which was equal to 2.17. This quantitative representation indicates that 64.18% of the nominal surface is occupied by re-entrants. The proposed approach offers a solution for evaluating MJF-produced surfaces, providing valuable insights for future surface measurement practices.
Patryk MIETLIŃSKI, François BERKMANS (Poznan / Poland), Tomasz BARTKOWIAK, Bartosz GAPIŃSKI, Maxence BIGERELLE, Michał WIECZOROWSKI
00:00 - 00:00 #40983 - Tribological study on solid lubricants at high temperature used in expansion machine.
Tribological study on solid lubricants at high temperature used in expansion machine.

In an internal combustion engine, more than 65% of the energy released by the fuel (gasoline, fuel oil or hydrogen) is rejected in the form of waste heat, 30% in the exhaust gas, and 35% in the engine cooling water. This loss encourages engine manufacturers to improve the energy efficiency of the machine. In order to take advantage of the energy available in the exhaust, different recovery technologies can be considered. The recovery of energy can be done in particular by a Rankine cycle where exhaust gases constitute the hot source of the cycle. The Rankine cycle is promising as several works have shown. The Rankine cycle is made up of a pump, two exchangers and an expander coupled to an electric generator. The heart of the Rankine cycle consists of the choice of the seal of the expander which will ensure the production of mechanical work. Currently, the market for volumetric expansion machines is limited and no expansion machine adapted to energy recovery conditions is available on the market. The development of a new expansion machine operating at high temperature to be able to recover small or medium power from exhaust gas is therefore necessary. In order to equip a scroll type expander with a seal to compress water vapor at high temperature, we carried out a tribological study on different pairs of materials. The seal must ensure both internal sealing function and thus limit losses through internal leaks from the expander. It must also have the lowest possible coefficient of friction in order to reduce friction losses. This joint is in fact stressed by plane friction stresses in an environment under water vapor at temperatures which can reach 250°C. These temperatures make the use of oil and the use of self-lubricating materials complex. The tribological study of the pin/disc type, to determine the pair of materials suitable for defining the joint, focused on the following pairs of materials (graphite/AU4G), Graphite/TiO2) and (Peek/TiO2). The TiO2 Coating was deposited by PVD – CVD evaporation at low temperatures below 450°C. The desired tribological properties are a low coefficient of friction, less than 0.1 and a low wear rate on large temperature range going from ambient temperature up to 250°C for relatively low contact pressures – 0.5 MPa – and sliding speed of the order of 1 to 2 m/s. These operating conditions were determined by complex modeling of the expansion machine by means of which the extreme conditions were simulated. The experiments have been made for a dry and a steam-lubricated contact at several temperatures. It enables us to characterize the frictional torque resistance and seal life required to size the thermal expander. The global discussion is mainly based on the experimental results and on the analysis and observations of wear particles and on worn surfaces.
Hamid ZAIDI (Poitiers - France)
08:00

"Monday 27 May"

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D1
08:00 - 09:30

Welcome and Registration

09:30

"Monday 27 May"

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D1-1
09:30 - 09:50

Opening Ceremony

09:50

"Monday 27 May"

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D1-Keynote1
09:50 - 10:30

Keynote Presentation 1

09:50 - 10:30 Surface topography and multi-physics functionality of engineering and living surfaces. Hassan ZAHOUANI (Professor) (Keynote Speaker, Ecully Cedex, France)
10:30

"Monday 27 May"

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D1-Session1
10:30 - 12:30

Surface, Micro and Nano Metrology

Moderator: Kalin MITJAN (Slovenia)
10:30 - 10:50 #38821 - Surface markings for the comparison of topography measurements.
Surface markings for the comparison of topography measurements.

For the evaluation of the surface topography only a small area of the surface in comparison to the whole workpiece is measured. Therefore, markings are needed as reference to relocate the measurement area. For the comparison of different optical or tactile measurement devices, Frühauf et al. manufactured silicon reference samples with etched marks [1]. Another application are before and after measurements to visualize and evaluate the change related to manufacturing processes. Newton et al. used micro-milled slots as relocation landmarks [2]. There is no description if and how they protected those landmarks during manufacturing. Moretti et al. describe algorithms for relocation based on landmarks that can be found both on the original and the manufactured surface [3]. This method can assess partial changes, since the landmarks of the original surface are needed. The relocation under the microscope is done by visual estimation. A proper reference is missing. With this paper new approaches with permanent abrasive markings for those applications are presented. A microscope (Confovis Duo Vario) executes the surface topography measurement. It combines confocal mode, that is used here, and focus variation mode. The surface data is processed with MountainsMap® 7. For the comparison of different optical measurement devices markings with the needle of a height marker are used on a milled surface (Figure 1a and b). In addition, a laser labels the different measurement areas (Figure 1a). The needle lines are used for positioning. They are excluded from the measurement. MountainsMap® provides the function colocalization to superimpose the different data (Figure 1c). Then profiles are extracted and compared to show similar behaviour (Figure 1d). Both devices generate comparable results. The second application are before and after measurements for a blasting process. As markings, Vickers hardness indentations are impressed. A 3D-printed cover protects the area with markings during the manufacturing process (Figure 2a, b and c). After blasting the before and after measurements are superimposed with the use of the indentations. Then profiles are extracted. The profiles show the change created by the impact of the blast media (Figure 2e). The paper will present the comparison by calculating differences for example in volume. As another example, the blasting of additive manufactured surfaces is analysed. The solution for markings depends on the application. The examined markings provide landmarks for proper relocation during the measurement and data evaluation.
Stefanie STÖCKEL (Chemnitz, Germany), Sophie GRÖGER
10:50 - 11:10 #38853 - Exploring Leaf Surface Characteristics for Mitigating Non-Exhaust Particulate Emissions in Transportation.
Exploring Leaf Surface Characteristics for Mitigating Non-Exhaust Particulate Emissions in Transportation.

Transportation-related air pollution, particularly fine particulate matter (PM) from non-exhaust sources, presents significant health and environmental challenges. Roadside vegetation has been recognized for its role in mitigating urban air pollution through the utilization of leaf attributes like surface roughness and trichomes, acting as natural PM filters [1, 2, 3, 4]. Despite potential variations in particle capture among plant species, a comprehensive understanding of the underlying mechanisms is lacking [5]. This study employs a two-phase approach, first by the identification of leaf characteristics that promote the retention of PM generated by tire wear. Subsequently, diverse plant species are chosen based on their attributes, intended to serve as barriers against the dispersion of PM. To simulate exposure to the PM source, a laboratory analytical setup was developed. Four well-adapted leaves from roadside vegetation in France were chosen, representing diverse surfaces with distinct retention mechanisms: Vanhouttei de spirala (1), Euonymus Europaeus (2), Cotoneaster aspressus (3), Cupressus leylandii (4). Using a binocular microscope and 3D optical profilometry, PM capture mechanisms and leaf surface characteristics were analyzed, identifying effective PM removal options among different plant species. This approach provided insights into particle-leaf surface interactions, evaluating size-dependent capture efficiency for effective PM removal. Observations revealed that both leaf topography and particle characteristics significantly influenced particle retention (Figure 1). Specifically, leaf 2 did not retain tire particles in the same manner as soil and aggregate particles, which were effectively captured by leaf 4. The study establishes correlations between leaf micromorphological features and pollutant capture, contributing to the design of effective plant barriers for air decontamination. In conclusion, it underscores the global importance of addressing health impacts resulting from non-exhaust PM emissions, emphasizing the necessity for proactive planning and interdisciplinary collaboration to implement efficient green infrastructure solutions.
Marilia RIBEIRO, Manuela LOPES GENNESSEAUX (Nantes - France), Bogdan MURESAN-PASLARU, Minh-Tan DO, Verônica CASTELO BRANCO
11:10 - 11:30 #38858 - Multiscale curvature characterization for multi-feature anisotropic surfaces.
Multiscale curvature characterization for multi-feature anisotropic surfaces.

Characterizing surface anisotropy is an important aspect of surface metrology considering it can be studied after a manufacturing process as quality control but also to predict and optimize the surface functionality. It helps researchers to understand how surface topography vary in different directions, which is essential for optimizing material performance and ensuring reliability in diverse applications, from industrial to medical. Surface anisotropy, being a parameter that changes with scale, requires a multiscale [1] approach to avoid biasing the results. However, conventional methods using the standard parameters as in ISO 25178-2 [2] are only relevant at a specific scale. The previous advancement in multiscale curvature characterization involved using curvature tensors to determine the most prominent directions for ridges and valleys [3]. That method allowed both quantifying and visualizing surface anisotropy. However, the concept of anisotropy can appear holistic when considering that a surface may exhibit various types of features. For instance, a milled and sandblasted surface or the skin texture, encompass different types of features. Our approach now is to isolate these features to create visualisation of directionalities and geometric characterizations in order to gain a better understanding surface anisotropy. Considering the curvature distribution for a given scale of observation distinctive modes can be considered as candidates for further extraction. For example, a flat surface with bidirectional groove pattern should produce evident peaks in the maximum curvature distribution for a scale related the size of these grooves. That peak should correspond to the inverse value of radii of the grooves. Adding the information about the maximum curvature direction, unidirectional grooves can be further extracted. Using color-coding features of similar morphologies can be visualized on the rendering of surface topography. In this study, we use canvass surfaces painted by both left-handed and right-handed individuals (Fig. 1a). These surfaces exhibit various trends and a strong anisotropy. The primary purpose of this experimentation is to seek relevant parameters to differentiate surface texture with the factor of handedness. This type of morphology exhibits features with a directional tendency. The valleys extracted at the scale of 40× original sampling interval are depicted in Figure 1b. The proposed method should contribute to better understanding the nature, sizes, and direction of surface features.
François BERKMANS (Poznan / Poland), Tomasz BARTKOWIAK, Michal WIECZOROWSKI, Maxence BIGERELLE
11:30 - 11:50 #38860 - Effect of polarisation on the accuracy of surface topography measurement results in coherence scanning interferometry.
Effect of polarisation on the accuracy of surface topography measurement results in coherence scanning interferometry.

In optical metrology, the growing applications of surface texture characterisation contribute to an increasing need for advanced measurement technologies [1]. Coherence scanning interferometry (CSI) is a popular technique in three-dimensional microscopy offering nanometre-level height resolution [2]. Various optical specifications and illumination features influence the accuracy of the surface topography measurement systems. In CSI, the bandwidth of the light source and the numerical aperture of the objective lens change the width of the coherence envelope and/or fringes along the z-axis [3], consequently affecting the accuracy of the measured surface topography. Moreover, the polarisation of the incident light plays an important role in topography measurement using CSI. The polarisation mode of the light can affect how it interacts with surface features. Certain surface structures may exhibit varying reflective or scattering properties based on the polarisation of the incident light. The effect of polarisation on the thickness and optical properties of thin films [4] and the batwing effect due to diffraction from sharp edges on the surface has been studied [5, 6]. The Boundary element method (BEM) is an electromagnetic light field scattering model that provides a rigorous solution to Maxwell’s equations [7]. The BEM model can predict the scattered light from diverse surface geometries, including complex features such as overhangs and undercuts, while accounting for the effect of the polarisation of the incident light [8]. In this study, BEM is used to model CSI (BEM-CSI) with a mean wavelength of 0.6 µm, full-width at half maximum wavelength bandwidth of 0.08 µm and a numerical aperture (NA) of 0.2. The effect of the polarisation of the incident light is investigated on the simulated interference signal corresponding to a silicon sinusoidal profile with a period of 4 µm, peak-to-valley of 0.2 µm and a complex refractive index of 4.289 + 0.0485i (see the red curve in Figure 1) using the BEM-CSI model. Figure 1 shows the cross-sectional view of the interference fringes in the xz-plane obtained by the BEM-CSI model for the (a) transverse electric (TE) and (b) transverse magnetic (TM) modes of the incident light. As depicted in Figure 1, various polarisation modes can introduce a phase shift in the interference pattern leading to errors in reconstructing the surface topography when employing a phase-dependant algorithm, such as Fourier domain analysis (FDA) [9]. Moreover, the visibility of the interference signal depends on the polarisation, thereby influencing the accuracy of the results. Figure 1 (a') and (b') illustrate the reconstructed profiles obtained by the interference pattern of Figure 1 (a) and (b) using the FDA algorithm. Figure 1 clarifies the necessity of choosing an appropriate polarisation to ensure accurate and reliable surface measurement results using a CSI instrument, particularly when dealing with materials or surface features that exhibit polarisation-dependent behaviours. In this study, the effect of polarisation on various surface topographies, and surface materials considering different NAs will be discussed.
Helia HOOSHMAND, Richard LEACH, Samanta PIANO (Nottingham, United Kingdom)
11:50 - 12:10 #40015 - Micro Gear Tolerance Optimization: A Hybrid Approach Combining Bayesian and Genetic Optimization Methods.
Micro Gear Tolerance Optimization: A Hybrid Approach Combining Bayesian and Genetic Optimization Methods.

In precision engineering, particularly in the context of micro gear production, stringent tolerance levels are essential for ensuring optimal functionality. Traditional tolerance design models in this field tend to focus primarily on product value, often overlooking aspects such as product robustness, which presents challenges in maintaining a balance between manufacturing precision and cost efficiency. This study proposes a hybrid optimization method that combines the predictive strengths of Bayesian techniques with the comprehensive search capabilities of genetic algorithms. This method is designed to address both precision and cost-effectiveness in micro gear manufacturing. The research methodology employed integrates statistical analysis with algorithmic modeling. Bayesian methods are utilized for forecasting and adjusting tolerance levels, using historical data and probabilistic models to enhance manufacturing accuracy. Concurrently, genetic algorithms are applied to explore a range of design parameters, aiming to identify optimal tolerance settings. This approach is known for its effectiveness in tackling complex optimization problems. The combination of these methods allows for an extensive exploration of potential solutions, seeking to achieve an equilibrium between precision and cost. Early results from this study suggest an improvement in tolerance optimization compared to traditional single-method approaches. The validation of this approach was conducted on a dataset comprising real-world micro gear manufacturing scenarios. The findings indicate that this method is applicable and effective in real-world manufacturing settings, offering a feasible approach to balancing precision and cost in micro gear production.
Jin JIN (Chengdu, China), Yuanping XU, Hongsheng FU, Yue ZHU, Tukun LI, Chao KONG, Dan TANG, Jian HUANG
12:30

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LUNCH D1
12:30 - 13:30

Lunch Break

13:30

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D3-Keynote2
13:30 - 14:10

Keynote Presentation 2

13:30 - 14:10 How to accelerate Green Hydrogen Project: Some metrological challenges. Olivier MACHET (dsds) (Keynote Speaker, dsd, France)
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D1-Session2
14:10 - 15:50

Metrology for smart manufacturing

Moderator: Cosimi CORLETO (STIL) (Aix-en-Provence Cedex 3, France)
14:10 - 14:30 #40676 - AI-Driven tribological approach applied to on- machine surface roughness prediction.
AI-Driven tribological approach applied to on- machine surface roughness prediction.

In the manufacturing industry, metrology assumes a critical role in affirming the quality of end products. [1] In cases where specific precision components fail to meet quality specifications, they are often scrapped, posing sustainability challenges for the manufacturing process. With the help of AI and smart sensors, we can move towards zero-defect manufacturing with an explainable approach. [2,3] Turn-mill machining center DMG is used to perform the cutting experiments. Apart from the machining parameters, a 3-axis dynamometer is used to record the cutting force. A chromatic confocal sensor was used to record the roughness as ground truth for on-machine measurement of roughness. 200 different cutting conditions were used to design experiments consisting of up and down milling. Instead of implicit feature extraction procedure with deep learning-based models, the work proposes a force lobe- based approach by creating windows within the force signals. Further different statistical features such as mean, standard deviation, skewness, kurtosis, crest factor etc were extracted from these windowed signals. Furtsssher these features were given as input to Machine learning model. Multiple ML models were tested but Random Forest was chosen as the base model because of its implicit explainability and overfitting handling criteria. Further, by experimenting with combinations across predefined parameter grids, grid search is used to methodically investigate and adjust hyperparameters for machine learning models, guaranteeing optimal performance. A regression model was developed to predict the roughness and a classification model was used to predict whether the signals belong to the category of Up or down milling based on the cutting force signals. The results show a strong correlation between the lobe-based features with the final output of prediction of surface roughness. This is validated from the waterfall graph showing the feature importance for the prediction models. This work is also the starting point of a proactive quality control model focusing on the process monitoring part.
Sourish GHOSH (Aix-en-Provence)
14:30 - 14:50 #40286 - Advanced Metrology for Smart Manufacturing: Integrating Optical Fiber and ETDR Technologies for High-Temperature Monitoring.
Advanced Metrology for Smart Manufacturing: Integrating Optical Fiber and ETDR Technologies for High-Temperature Monitoring.

In the domain of smart manufacturing, precise temperature monitoring is crucial, particularly for assets like arch, kiln, or arc furnaces in industries such as foundry and glass production. Traditional methods like thermocouples offer only sporadic and isolated measurements. To address this limitation, recent advancements in Optical Time Domain Reflectometry (OTDR) have enabled distributed temperature measurements. However, the applicability of optical fibers is constrained to temperatures below 700°C, due to durability concerns over extended industrial usage. This paper presents a comprehensive study on the deployment of Optical Fiber and Electrical Time Domain Reflectometry (ETDR) technologies, tailored for high-temperature monitoring in industrial environments. The focus is on the development of robust sensors capable of enduring extreme conditions, particularly temperatures above 700°C, where OTDR sensors reach their limits. For temperatures below 700°C, the utilization of optical fibers presents a viable solution. The study elaborates on the advancements in optical fiber technology, particularly in enhancing their temperature endurance and measurement accuracy, making them suitable for a wide range of industrial applications. In the context of higher temperatures, ETDR sensors emerge as a promising alternative. The study introduces an innovative ETDR-based sensor system, capable of enduring and accurately measuring temperatures beyond the threshold of optical fibers. This system employs a high-frequency electro-magnetic signal within a transmission line composed of materials specifically chosen for high temperature and durability. The backscattered signal analysis from these ETDR sensors provides a distributed and continuous temperature profile along the sensor line. A significant portion of the study is dedicated to material selection and aging properties to optimize the response of ETDR sensors to high temperatures. Various materials, including alumina as a dielectric and different metals as conductors, are investigated for their suitability in ETDR systems. The paper discusses the experimental and modeling approaches employed to identify the most efficient material combinations and sensor geometries, considering factors like permittivity, resistivity, permeability, and environmental influences such as temperature, humidity, and mechanical strain. The paper aims to promote the development of these new technologies, offering a pathway towards more efficient and reliable temperature monitoring in smart manufacturing settings. By integrating optical fiber and ETDR technologies, the study paves the way for enhanced monitoring capabilities, contributing to the safety, efficiency, and longevity of various industrial processes. Main References [1] F.-K. Chang, Structural health monitoring 2000. CRC Press, 1999. [2] J. A. Stastny, C. A. Rogers, and C. Liang, "Distributed electrical time domain reflectometry (ETDR) structural sensors: design models and proof-of-concept experiments," in Smart Structures and Materials 1993: Smart Sensing, Processing, and Instrumentation, 1993, vol. 1918: International Society for Optics and Photonics, pp. 366-376. [3] R. H. Cole, "Time domain reflectometry," Annual review of physical chemistry, vol. 28, no. 1, pp. 283-300, 1977. [4] S. B. Jones, J. M. Wraith, and D. Or, "Time domain reflectometry measurement principles and applications," Hydrological processes, vol. 16, no. 1, pp. 141-153, 2002. [5] B. M. Lee, K. J. Loh, and F. L. di Scalea, "Distributed Strain Sensing Using Electrical Time Domain Reflectometry With Nanocomposites," IEEE Sensors Journal, vol. 18, no. 23, pp. 9515-9525, 2018. [6] S. Sun et al., "A novel TDR-based coaxial cable sensor for crack/strain sensing in reinforced concrete structures," IEEE Transactions on Instrumentation and Measurement, vol. 58, no. 8, pp. 2714 2725, 2009. [7] T. Wei, S. Wu, J. Huang, H. Xiao, and J. Fan, "Coaxial cable Bragg grating," Applied Physics Letters, vol. 99, no. 11, p. 113517, 2011. [8] Z. Zhou, T. Jiao, P. Zhao, J. Liu, and H. Xiao, "Development of a distributed crack sensor using coaxial cable," Sensors, vol. 16, no. 8, p. 1198, 2016.
Mickael BOINET (Cavaillon)
14:50 - 15:10 #39005 - A novel semiempirical model for predicting bulge generation in femtosecond laser ablation processes.
A novel semiempirical model for predicting bulge generation in femtosecond laser ablation processes.

Femtosecond lasers offer significant advantage in precision manufacturing due to the ability to create surface textures with a minimal heat affected zone avoiding undesirable bulges that can alter the functionality of the surface in applications such as tribology [1]. The selection of optimal parameters for achieving bulge free textures remains a complex task based on trial-and-error approaches. Current heat accumulation prediction models assume that the unused ablation energy remains in the material as residual heat, leading to thermal damage prediction [2]. Nevertheless, these models do not predict bulge generation. This study presents a new semiempirical model for bulge generation prediction in multi-shot dimple and line ablation. The model is based on the mean energy delivered per unit area throughout the ablation process, i.e. the accumulated fluence, and validated through the measurement of the generated bulges. A femtosecond laser was used to ablate multi-shot dimples and lines with various process parameters combinations. Sensofar 3D optical profiler employing confocal technology with EPI100X objective was used to measure the generated geometry, and bulge’s mean and maximum height and volume were characterized (see Figure 1). After analysing the evolution of the mean and maximum height and volume of the bulges with the accumulated fluence, a relationship with the bulge’s volume was found as observed in Figure 2 (a). Results indicated two regimes: (i) absence of bulge generation and (ii) bulge generation, with logarithmic increase of the normalized volume as the accumulated fluence rise (see Figure 2 (b)). This trend was consistent for both dimples and lines with limits for bulge formation calculated at 31.48 ± 8.8 J/cm2 and 30.67 ± 13.7 J/cm2 respectively. The study concludes that accumulated fluence serves as a viable metric for establishing a limit for bulge generation. Incorporating the limit of accumulated fluence into existing prediction models for laser ablation profiles represents an improvement as it guarantees the selection of process parameters that create textures with bulge-free edges without the need of trial and error.
Ainhoa GUINEA (Mondragon, Spain), Andrea AGINAGALDE, Joseba MENDIGUREN, Iñigo LLAVORI, Wilson TATO, Eneko SAENZ DE ARGANDOÑA, Alaitz ZABALA
15:10 - 15:30 #40036 - Progress toward compact spectrometry realised via metasurfaces.
Progress toward compact spectrometry realised via metasurfaces.

To optimally deploy optical instrumentation more widely within manufacturing chains and aid a move towards Industry 4.0, sensors need to be developed in a form more suitable for integration [1]. Current optical instrumentation is often too bulky and heavy to perform in-process and on-machine measurements within manufacturing systems without interfering with ongoing processes. One reason why current instrumentation is too large is the number and size of the optical components, such as glass lenses, utilised in their construction. A reduction in the size or number of these elements would allow significantly more compact optical instruments to be created. One instrument we have particular interest in is a Single-shot Dispersive Profile Interferometer (SDPI) [2], which is designed to take on-machine measurements of the surfaces of moving substrates in roll-to-roll processes for printed electronics. In an SDPI, light from the image of a line on the measurand surface and that from a reference beam is combined before being separated out by wavelength in a direction perpendicular to the measurement line, producing a spectrum for each point along it. The variation of intensity within the spectrum from each point encodes the height of the surface at that location, allowing a profile to be determined from a single image. The determination of the spectrum at each point along the line is currently carried out using a traditional form of spectrometer, one that requires multiple components to separate the different wavelengths of light and focus them onto different regions on an areal CCD/CMOS detector. However, in this form the spectrometer takes up a significant portion of the size of the overall instrument which limits it potential for integration. Photonic metasurfaces are an emerging technology which allows the manipulation of light without the bulk of traditional optical elements, with elements having a thickness on the order of the wavelength of light. Furthermore, they can be designed to perform multiple functions simultaneously, reducing the need for the multiple optical elements required in many applications [3]. Here we present our work towards developing a single metasurface element that combines focussing and wavelength separation functions, allowing a spectrometer to be formed with just the addition of a detector [4]. This approach can significantly reduce the size of the spectrometer, lowering the number of elements that need to be aligned (and maintained in alignment). The metasurfaces utilised here uses the truncated waveguide approach and consists of an array of GaN nanopillars fabricated on an Al_2 O_3 substrate. By varying the form of the pillars across the surface, the phase delay imparted on the light can be changed by up to 2π radians, and in this way incident wavefronts can be reshaped arbitrarily as they pass through. The spectrometer harnesses the strong chromatic aberration that is present with basic metalenses of this form in order to angularly separate the light. The metasurface is designed to take light from a specific point, and at a specific wavelength, on the object side of the metasurface and focus it to a point on the detector side. The chromatic aberration present leads to a shift of the focal point on the detector side for other wavelengths (see figure 1). A shift of the point source in the y-direction corresponds to a shift where the spectra is formed. In this way the spectrometer required by the SDPI is formed. Here we will present details on the design, fabrication, and characterisation of the metasurface-based spectrometer, which is a crucial stepping stone to developing a more compact SDPI instrument in the near future.
Andrew HENNING, Joseph KENDRICK (Huddersfield, United Kingdom), Haydn MARTIN, James WILLIAMSON, Dawei TANG, Nityanand SHARMA, Xiang (Jane) JIANG
15:30 - 15:50 #38747 - A novel data fusion pipeline for point cloud registration.
A novel data fusion pipeline for point cloud registration.

In this work, we propose a data fusion pipeline for registering two point clouds that have a distinct disparity in the size and point density: one point cloud is large and sparse, while the other is small and dense. The small and dense point cloud represents the surface texture details of a region located within the large and sparse point cloud. The motivation behind the data fusion pipeline proposed in this work is that most of the latest data fusion algorithms are only applicable to point clouds with similar sizes and point densities. In this algorithmic pipeline, firstly, the large and sparse point cloud is defined as the reference and it is segmented into subsections (“sub-clouds”), each of which is sized identically to the small and dense point cloud. Then, the distances between points and the plane formed by two of the main axes (principal component analysis – PCA) are calculated and plotted into histograms for the small and dense point clouds and each sub-cloud. Sub-clouds showing similar histograms to the small point cloud’s histogram are selected as candidates. In the next step, the angles between local normal vectors and the PCA-plane are calculated and plotted into histograms for the small and dense point cloud and all candidate sub-clouds. The sub-cloud generating the most similar histogram to the small point cloud’s histogram is determined as the best matching. The small point cloud is then transferred into the coordinate frame of the large point cloud and translated to the target sub-cloud’s location. The next step is to determine the correct orientation of the small point cloud: the small point cloud is rotated around 360° in 10° intervals and voxelised into (10 × 10) voxels on the x-y plane and five layers along the z-axis (i.e. 500 voxels in total for each point cloud). The target sub-cloud is voxelised simultaneously with the same configuration. The percentage of points falling in each voxel (i.e. the percentage relative to the total number of points in the processed point cloud) is then calculated. The voxels of the small point clouds and each candidate sub-clouds are compared : if two corresponding voxels for these two point clouds have similar percentages, this pair is defined as a good match. Finally, the orientation of the small point cloud which gives the largest number of matched voxel pairs is determined as the correct orientation for registration. The proposed pipeline has been tested on synthetic three-dimensional models characterised by artificial engineered surfaces.
Zhongyi Michael ZHANG (Nottingham, United Kingdom), Adam THOMPSON, Sofia CATALUCCI, Samanta PIANO
15:50

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CB
15:50 - 16:10

Coffee Break

16:10

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D1-Session3
16:10 - 17:50

Measurement, Instrumentation & Characterization in Metrology

Moderator: Mustapha EL BOUCHOUAFI (General Manager ZEISS IQR) (Rueil Malmaison, France)
16:10 - 16:30 #40313 - Characterization of the tactile perception of textured materials for packaging.
Characterization of the tactile perception of textured materials for packaging.

The Textures are becoming more and more key in the perceived value of our packaging, in the adequation between formula and packaging and for our consumers experience. Our objectives in terms of sustainability and recyclability lead us to reduce the diversity of type of materials that we can use but also we need to increase the diversity of sensorial tactile textures and consumer experience.The diversity of textures achievable on a packaging is also a large territory of technical improvements. All these needs create the necessity of having an objective and quantitative way to characterize and evaluate a texture and its corresponding tactile perception. This work aims to develop new knowledge and establish a multisensory database (roughness, touch) to facilitate the substitution of conventional plastic packaging solutions with more environmentally friendly alternatives, while reducing post-processing steps (varnishes, paints) that negatively impact the recyclability of products. We conducted a cross-study on the roughness and touch of materials used in packaging manufacturing. The goal was to establish a classification of the tactile sensorial properties of the samples. Initially, we analyzed the surface roughness with a multi-scale wavelet analysis method [1]. This method allows quantifying each wavelength family composing the surfacewith the roughness criterion SMa, representing the average value of the signal amplitude for a given wavelength. The results are presented in the form of an SMa roughness criterion spectrum, ranging from small to large wavelengths, forming a unique and multispectral signature of the surface topography signal. Secondly, we measured the tactile sensorial vibrations of the samples using an electonical finger. Thirdlyl, we measured the tactile sensorial properties of the samples using an electonical finger and TouchFinger [2], an innovative device simulating an augmented human finger. When we touch the surface of an object with our index finger, the friction of the finger's skin on the surface vibrates the mechanoreceptors located in the finger pulp [3]. The vibratory response is then instantly converted into an electrical signal, transmitted via the central nervous system to the brain, which interprets this information as the sensory quality of the surface. Like the human finger, the device is equipped with vibration sensors and a force measurement sensor. It comes in the form of a half-ring that slips onto the tip of the index finger. When touching a surface, the vibrations and the force recorded by the device are transformed into tactile quality parameters for each of the four mechanoreceptors: Pacinian, Ruffini, Merkel, and Meissner [4][5]. The experimental protocol was conducted on a diversity of materials : cardboard, glass, aluminium, PET, PP, recycled PP, recycled PET; and a diversity of Textures achieved by mechanical or chemical treatment, spraying deposit and laser engraving . All samples were measured in topography with a white light confocal device, then characterized with the SMa parameter by the 2D continuous wavelet method. For the evaluation of the touch of the samples, a panel of 10 people aged 22 to 25 years was formed. Measurements were performed with the TouchFinger device in a temperature-controlled room (21°C +/- 2°C) and humidity (50% +/- 5%). For each surface, the panelists performed three successive touches and replicated the measurement three times. The vibratory signals obtained were analyzed by a frequency decomposition method to calculate the mean vibratory level (La parameter (dB)) in each of the mechanoreceptor frequency bands. The average values obtained of the La (dB) parameter for each of the mechanoreceptors were analyzed in correlation with the surface topography parameters. The results obtained allow establishing a database of the tactile quality of reference samples based on their material and texture.
Hassan ZAHOUANI (Ecully Cedex), Roberto VARGIOLU, Nicolas DURU, Corentin PERRAIS, Gustavo LUENGO, Olivier DELATAULADE
16:30 - 16:50 #38862 - Detection and analysis of re-entrant features created on additively manufactured surfaces.
Detection and analysis of re-entrant features created on additively manufactured surfaces.

The aim of this research is to detect re-entrant features which are a signature of the additive manufacturing process that involve sintering or melting of metal or plastic powders. Conventional surface measurement techniques such as profilometry or optical microscopy consider measured surface as a function z=z(x,y), meaning that for any given location on the surface (x, y), there is only one unique height (z). These techniques work well for surfaces whose shape can be locally approximated using a plane, cylinder, or ellipsoid, or for surfaces considered at a large scale of observation. For freeform surfaces with complex geometry, consisting of pores, voids, cracks, or overhangs being present at the microscale, and resulting from incompletely sintered or melted powder or the turbulent interaction of a laser energy beam, these so-called re-entrant features are impossible to register due to the physical limitations of optical and contact methods[1]. With the development of metrological high-resolution X-ray microcomputed tomography, it has become possible to study regions of surfaces invisible to other techniques. However, due to the implicit representation of the surface, a change in the approach to its parametric and non-parametric description, especially present in ISO or ASME standards, is necessary [2-3]. The subject of this study are parts produced using Selective Laser Melting technology. The input material Ti-6AL-4V powder with a grain size between 15 µm and 45 µm. The geometry of the samples was a quarter cylinder with a radius of 5 mm and a height of 25 mm. The samples were produced using EOS M290 machine. To achieve a large diversity of surface morphology, process parameters were varied: laser power (between 107 and 267 W) and scanning speed (between 250 mm/s and 1000 mm/s). The samples were not subjected to any additional finishing processing. The surface topography was registered using Baker Hughes/General Electric v|tome|x s240 microCT scanner, obtaining a voxel size of 5.5 µm. On each of the reconstructed 3D models of the sample surfaces, every 0.1 mm, 20 roughness profiles along the build-up direction were extracted. Each profile was averaged using a B-spline curve, assuming it as the local form. For each point of the original profile, its projection onto the form profile was determined, and then it was checked whether the coordinates of the subsequent projected points increased in the same direction as the coordinates of the form profile. If the local direction of increase changes, it means that a local re-entrant feature has been detected. A large number of such features may indicate inappropriately selected parameters of the technological process or disqualify other measurement techniques for credible registration of the surface topography. On the other hand, a small number of re-entrant features may suggest that an alternative measurement using profilometry or optical microscopy adequately reproduces the given SGP. The frequency of occurrence of these features, in the context of laser beam power and scanning speed, is the subject of analysis in this article. Exemplary results of detected re-entrant features and the effect of technological parameters on the frequency of their occurrence is shown in Figure 1.
Tomasz BARTKOWIAK (Poznan, Poland)
16:50 - 17:10 #39884 - Bio-engineering of perfume interaction with human skin and olfactory sensoriality.
Bio-engineering of perfume interaction with human skin and olfactory sensoriality.

Perfume is a complex composition of odorants and solvents, with a variety of physico-chemical characteristics such as volatility, molecular weight and vapor pressure, in addition to their unique olfactory properties. When perfume is applied to the skin, only part of its components is perceptible to the human sense of smell, and this perception depends on many factors such as the physico-chemical properties of each molecule, the interactions between the ingredients in the perfume formula and the surface to which it is applied, such as the skin. In addition, external factors can influence the evaporation of odorants, which can lead to significant variations in concentration profiles, even for similar doses. Given that the sensory performance of fragranced products is crucial, it is of great interest to understand how the skin can influence the behaviour of a fragrance. Consequently, methods are needed to characterize the interaction of fragrance with the human skin surface. Raman spectroscopy is proving to be a fast, non-invasive analytical technique, ideal for investigating the molecular mechanisms involved in the interactions between different types of fragrance and the human skin. In this study, we examined the performance of different fragrances on ex vivo skin as a function of time using Raman spectroscopy. We discuss the most important bands observed in the Raman spectra, and also present results concerning the characterization of different skin types, including proteins, sebum content and hydration level. Finally, we have classified these skin types according to these different parameters.
Emilie KHATTIGNAVONG (LYON), Hassan ZAHOUANI, Roberto VARGIOLU, Sophie RAVIOT-DERRIEN
17:10 - 17:30 #40001 - Deterministic form-position deflectometric measurement of transparent optics.
Deterministic form-position deflectometric measurement of transparent optics.

Deflectometry is a powerful measuring technique of complex optical surfaces. It has extremely high sensitivity to surface slopes, but the in most cases, the measurement accuracy can only achieve a level of microns. The main limiting factors of the measurement accuracy are investigated. A flexible camera model and an automatic calibration method are developed. The geometrical pose and location of the workpiece are solved by minimizing the re-projection error of ray-tracing, and an automatic positioning method is proposed by combining the Gaussian process regression.
Xiangchao ZHANG (Shanghai, China)
17:30 - 17:50 #40304 - Ecological niche partitioning revealed among Theropod dinosaurs through Dental Microwear Texture Analysis.
Ecological niche partitioning revealed among Theropod dinosaurs through Dental Microwear Texture Analysis.

Most predatory theropod dinosaurs, excluding spinosaurs, have long been thought to retain the plesiomorphic dinosaurian condition of carnivory. The presence of numerous, similar sympatric medium- to large-bodied predatory taxa in localities such as the Bahariya, Huincul and Morrison formations therefore raise questions regarding ecosystem structure. Spinosaurs are known for piscivory and possess adaptations for subaqueous feeding and locomotion, whereas their sister clade, megalosaurids have generally been considered to include only terrestrial predators. However, increasing evidence suggests that megalosaurids, especially European taxa, had a preference for feeding in mesic and aquatic environments. Establishing dinosaurian diets have often relied on tooth morphology or stomach contents, both which have limitations, such as convergent morphology in the case of the former or capturing fall-back foods rather than usual diet in the case of the latter. Moreover, tooth morphology usually recognises broad dietary guilds, such as herbivory or carnivory, only. Recent work on extant and extinct archosaurs and lepidosaurs have shown that dietary guilds can be determined for fossil taxa more precisely, including categories like hard or soft invertebrate diets, carnivory and piscivory, among others, by using Dental Microwear Texture Analysis (DMTA)1,2,3. Using a confocal microscopy and dental moulds, the 3D surface textures of a theropod tooth sample were analysed at 100x magnification using common parameters from the literature 1,2 . Preliminary results suggest that predatory theropod diets were more diverse than previously thought, with megalosaurids showing evidence for piscivory and tyrannosauroids (the clade that includes Tyrannosaurus rex) potentially exhibiting non-carnivory in their diets. Consequently, niche partitioning might have occurred between sympatric theropod taxa due to specialisations in their diets that prevented direct competition. Furthermore, application of DMTA along the tooth rows within individual theropod jaws might allow the method of prey acquisition to be determined based on serial variation in the microwear patterns of the teeth with the potential to test biomechanical models.
Cassius MORRISON (London, United Kingdom), Philip MANNION, Laura PORRO, Liam BLUNT, Paul BILLS, Paul BARRETT