The common measurement error when measuring the component geometrical dimensions using universal contact measurement instruments is caused by different factors, such as error of the measurement instrument, personal reading errors, effect of surface roughness on the measuring line deviation, influence of contact deformation measurement force, and others. The present article examines one of these factors, i.e. contact deformations under the influence of measurement force. To make precise measurements it is essential to find out the effect of roughness of measured components. High roughness creates additional measurement errors. It is particularly important in the measurement of thin components, flexible materials and films, as well as for components with nanocoating. Flexible bodies in the meaning of this article are components of different shape and sizes made of rubber or soft plastic. This article studies principles of error formation based on the deformation of surface roughness and basic material.
In this paper, calculations of 3D parameter Vm (material volume) of surfaces with irregular roughness and comparison with experimental data were performed, with further application of this parameter in calculations of wear intensity. First, using Mountains Map software for profilometric measurements, 3D roughness processing and determination of material volume Vm at specific relative levels γ were performed. The next step was an additional analysis of the distribution of surface ordinates using a theoretical and experimental Laplace function. The given check confirmed that for mostly surfaces with irregular roughness the ordinate distribution corresponds to the normal Gaussian distribution law, but in cases when the asymmetry of the ordinate distribution function goes outside the permissible limits (|∆Ssk|> 10%), errors> 10 % occur. On this basis, the mathematical formula of the material volume Vm was derived, and the obtained calculations were compared with the measured values. The results showed that the calculated values of the parameter Vm were very close to the experimental data (|∆Vm|<10 %), while at the relative level γ=+3, errors occurred that was related to the deviation from the normal distribution law. It was concluded that the given parameter could be used in the calculations of linear wear intensity, knowing the relative level γ.
One of the most important parameters in determination of the deformation associated with roughness is its height on the surface. The authors study the density of probability distribution as related to the surface peak height (SPH) and estimate the mathematical expectation (ME) of SPH for the roughness values above a determined deformation level. In the contact theory, the surface is modelled as a normal random field described by the Nayak SPH formula. Since this formula is practically inapplicable in the engineering tasks, the authors propose to replace it by a simpler distribution law. For this purpose the former is compared with two other formulas obeying the most known probability distribution laws: of normal distribution (Gauss’) law and Rayleigh’s law. Comparison of these three formulas made it possible to derive a simpler yet sufficiently precise one. In the work, the numerical values of the density of SPH probability distribution and the relevant ME values at different deformation levels for all three formulas.
A number of different mechanisms and devices may involve sliding-friction surfaces. The issues of service life and its prediction for the details of such surfaces have always been of particular importance. The article determines the most suitable wear calculation model that allows considering the set of parameters necessary for calculating slide-friction pair. The offered model is based on the application of the theories of several branches of sciences. Since the wear process is variable and many-sided, it is influenced by numerous different parameters, for example, surface geometry (roughness, waviness, form deviation, etc.), physical and mechanical conditions of the upper layer, material components, wear regime, wear temperature, etc.
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