The relationship between machining and the surface produced is not fully understood, for example, in biomedical applications the surface should not be too smooth while at the same time not be too rough so that the cells will not adhere to it. To gain a better knowledge of this relationship it is necessary to fully understand the major aspects such as the tool, the workpiece and the interaction between them - this can only be achieved through modeling and experimental verification.
Research is being carried out on investigating a number of machining and abrasive processes including precision grinding and chemical mechanical polishing. The team currently consists of PhD, MEng, MSc, and final year students (see below).
Techniques employed include advanced topographical characterisation, cutting forces analysis and wear measurements.
 | Kistler dynanometer |
| ABAQUS FE software |
| DI Dimension AFM |
| Taylor Hobson Talyscan 150 |
| Okuma CNC lathe |
| Okamato Grinding machine |
Current Research activities include the modeling of the ultra-precision grinding process, the topographic characterisation and optimisation of the turning, electro-discharge machining and turning processes as well as specific industry-related projects for the aerospace industry.
| Modelling and
Topographic Study of the Precision Grinding Process
Candidate: Mr Nguyen Tuan Anh Degree : PhD Start: August 2001 Completed : November 2004 This work is aimed at providing a better understanding of the grinding process through the development of better simulation models combined with the topographic analysis of both the wheel and workpiece. Utilising the Birmingham set of three-dimensional surface parameters and combining with a novel optimal measurement strategy, a new insight into the wheel-workpiece interaction is possible. The support of SIMTECH is gratefully acknowledged.
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| Investigation into the
relationship between turning parameters and surface
topography Candidate: Miss Toh Shi Mei, Mable Degree : BEng (Hons) Start: July 2004 This project involves an investigation into the effect of varying the machining parameters on the turned workpiece surface. The material selected is Inconel 718 - a nickel-based alloy and the machining inserts are cemented carbides. The project should hopefully provide a clearer guideline on the effects of rake angles on the topography generated. |
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| Investigation into the
relationship between vibration induced by turning and surface
topography Candidate: Miss He Jiani Degree : BEng (Hons) Start: July 2004
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It has long been known that a round bar should be
ideally supported between centres if any machining is to
take place. This project involves an investigation into the
effect of varying the machining parameters on an
unsupported turned
workpiece surface. The effect vibration becomes all too
apparent when the surface topography is examined and
characterised. It is intended that a parameter suite
will be developed which can accurately predict this
topographic variation.
| Title | Student | Completed | Degree |
| Investigation into the relationship between turning parameters and surface topography | Toh Shi Mei,Mable | May 2005 | BEng |
| Surface Grinding The relationship between surface topography and machining conditions | He Jiani | May 2005 | BEng |
| An investigation into the milling process using topographic characterisation | Ho Kok Boon | May 2005 | BEng |
| A study of the Surface Grinding Process through topographic characterisation | Lee Khai Wah,Laurance | May 2005 | BEng |
| The development of a empirical model to predict the topography of turned surfaces. | Liau Siong Chang | May 2004 | BEng |
| Precision Ground Surfaces: The relationship between surface topography and machining conditions | Peh Wei Loong,Jeremy | May 2004 | BEng |
| The topographic characterisation of electro-discharge machining | Lim Tian Soon | May 2004 | BEng |
| The Optimisation of the Precision Surface Grinding Process for Aerospace Alloys through topographic characterisation (Diamond Wheels) | Chan Sze Chiew | May 2003 | BEng |
| The Optimisation of the Precision Turning Process of Aerospace Alloys through 3-D Surface Characterisation | Chua Chern Yi | May 2003 | BEng |
| The optimisation of the precision turning process through 3-D surface characterisation | Yap Kong Lin | May 2003 | BEng |
| The Optimisation of the Precision Surface Grinding Process through topographic characterisation (Conventional Wheels | Seah Wilson | May 2003 | BEng |
| The Topographic Characterisation and Optimisation of Dressing Conditions for Surface Grinding | Hong Chee Yong,Thomas | Dec 2002 | BEng |
| The optimisation of turning through topographic characterisation | M.C.V Mathai |
Dec 2002 |
MSc(Eng) |
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T.A. Nguyen and D.L. Butler, Correlation Length –Based Sampling Conditions for Various Engineering Surfaces, Measurement Science and Technology, Accepted for Publication, March 2005
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T.A. Nguyen and D.L. Butler, Simulation of Surface Grinding Process, Part 1: Generation of the Grinding Wheel Surface, International Journal of Machine Tools and Manufacture, Volume 45, Issue 11,
September 2005 ,Pages 1321-1328. -
T.A. Nguyen and D.L. Butler, Simulation of Surface Grinding Process, Part 2: Interaction of the Abrasive Grain with the Workpiece, International Journal of Machine Tools and Manufacture, Volume 45, Issue 11,
September 2005 ,Pages 1329-1336. -
Nguyen T.A, D.L. Butler, "Simulation of Precision Grinding Process for Predicting Surface Roughness", MATADOR, Manchester, July 2004
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T.A. Nguyen, Butler D.L., "A Methodology for Simulation of Grinding Wheel Surfaces for Precision Surface Grinding" , ICoPE 2003/04, Singapore, March 2004
Butler D.L., S.C Chan, K. Ramesh, H. Huang, "CBN Grinding of Inconel- A Topographic Approach to Process Characterisation", ICoPE 2003/04, Singapore, March 2004
D. L. Butler, L. A. Blunt, B. K. See, J. A. Webster and K. J. Stout, "The characterisation of grinding wheels using 3D surface measurement techniques", Journal of Materials Processing Technology, Volume 127, Issue 2, 30 September 2002, Pages 234-237
D.L. Butler, L.A. Blunt, B.K. See, J.A. Webster, and K.J. Stout, "The Characterisation of Grinding Wheels using three-dimensional surface measurement techniques", ICoPE 2000, Singapore March 2000
Butler D.L., J. Webster, Liam Blunt, and K.J. Stout, "The Three-Dimensional Surface Topographic Characterisation Of Conventional And Superabrasive Grinding Wheels", ASPE Annual Conference, California, October 1999