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Publications (10 of 20) Show all publications
Rebeggiani, S., Wagner, M., Mazal, J., Rosén, B. G. & Dahlén, M. (2018). Detection of paint polishing defects. Paper presented at Met and Props 2017, Gothenburg, Sweden, 27-29 June, 2017. Surface Topography: Metrology and Properties, 6(2), Article ID 024009.
Open this publication in new window or tab >>Detection of paint polishing defects
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2018 (English)In: Surface Topography: Metrology and Properties, ISSN 2051-672X, Vol. 6, no 2, article id 024009Article in journal (Refereed) Published
Abstract [en]

Surface finish plays a major role on perceived product quality, and is the first thing a potential buyer sees. Today end-of-line repairs of the body of cars and trucks are inevitably to secure required surface quality. Defects that occur in the paint shop, like dust particles, are eliminated by manual sanding/polishing which lead to other types of defects when the last polishing step is not performed correctly or not fully completed. One of those defects is known as 'polishing roses' or holograms, which are incredibly hard to detect in artificial light but are clearly visible in sunlight.

This paper will present the first tests with a measurement set-up newly developed to measure and analyse polishing roses. The results showed good correlations to human visual evaluations where repaired panels were estimated based on the defects' intensity, severity and viewing angle.

Place, publisher, year, edition, pages
Bristol: Institute of Physics Publishing (IOPP), 2018
Keywords
Metrology, coating, polishing, surface finish, surface estimation
National Category
Other Mechanical Engineering
Identifiers
urn:nbn:se:hh:diva-37400 (URN)10.1088/2051-672X/aabfb5 (DOI)000432868700002 ()
Conference
Met and Props 2017, Gothenburg, Sweden, 27-29 June, 2017
Projects
Robust Polering
Funder
Vinnova, 2015-06889
Available from: 2018-06-29 Created: 2018-06-29 Last updated: 2019-04-26Bibliographically approved
Rebeggiani, S., Flemming, L., Rosén, B.-G. & Blunt, L. (2014). A Training Consortium to Explore and Exploit Surface Metrology. In: : . Paper presented at SPS'14, The 6th Swedish Production Symposium, Gothenburg, Sweden, September 16-18, 2014.
Open this publication in new window or tab >>A Training Consortium to Explore and Exploit Surface Metrology
2014 (English)Conference paper, Published paper (Other academic)
Abstract [en]

The importance of surface finish in all aspects of manufacturing influences economic considerations as well as environmental aspects and functionality. The ability to effective and efficient characterise surface topography is an important tool in the manufacturers arsenal which is often overlooked or underutilised. By providing a comprehensive, affordable training package, a gap in the industrial knowledge is filled giving manufacturers the ability to increase their competitive edge.

Keywords
surface metrology, education, knowledge transfer
National Category
Other Mechanical Engineering
Identifiers
urn:nbn:se:hh:diva-27152 (URN)
Conference
SPS'14, The 6th Swedish Production Symposium, Gothenburg, Sweden, September 16-18, 2014
Available from: 2014-12-01 Created: 2014-12-01 Last updated: 2018-03-22Bibliographically approved
Rebeggiani, S., Dimkovski, Z., Kofod, G. & Rosén, B.-G. (2014). Empirical Evaluation of Spin-on-Glass-Layers on Steel Surfaces by Wear Tests. Tribologia Finnish Journal of Tribology, 32(1), 19-24
Open this publication in new window or tab >>Empirical Evaluation of Spin-on-Glass-Layers on Steel Surfaces by Wear Tests
2014 (English)In: Tribologia Finnish Journal of Tribology, ISSN 0780-2285, Vol. 32, no 1, p. 19-24Article in journal (Refereed) Published
Abstract [en]

Dies and moulds with high precision surfaces are being used in various branches, e.g. in the plastic industry where the surface finish are conventionally performed by manual polishers. With ever increasing demands of shorter lead times and reduced costs, efforts have been made to automate this finishing process. This paper presents an empirical study performed to test durability properties of SOG (spin-on-glass)-layers on steel surfaces. The results showed that the thin coating last longer than the thicker ones, and that the harder coatings withstood wear significantly better than the steel reference samples thus motivating further investigations.

Place, publisher, year, edition, pages
Helsinki, Finland: Helsinki University of Technology, 2014
Keywords
Injection moulding, surface finish, tribometer, ball-on-disk, SOG-layers
National Category
Tribology (Interacting Surfaces including Friction, Lubrication and Wear)
Identifiers
urn:nbn:se:hh:diva-27153 (URN)2-s2.0-84910601772 (Scopus ID)
Available from: 2014-12-01 Created: 2014-12-01 Last updated: 2018-01-11Bibliographically approved
Dimkovski, Z., Kofod, G., Rebeggiani, S. & Rosén, B.-G. (2014). Evaluation of Durability of SOG-layers on Steel Surfaces by Wear and Scratch Tests. In: : . Paper presented at The 16th Nordic Symposium on Tribology - NORDTRIB 2014, Aarhus, Denmark, 10-13 June, 2014.
Open this publication in new window or tab >>Evaluation of Durability of SOG-layers on Steel Surfaces by Wear and Scratch Tests
2014 (English)Conference paper, Oral presentation with published abstract (Refereed)
Abstract [en]

Steel moulds with high precision surfaces are being used in various branches. Process aspects, like tool life and tribological properties, as well as design issues are of great importance. This work summarises experimental studies performed to test durability properties of SOG (spin-on-glass)-layers on steel surfaces. This coating technique is based on a newly developed method for surface preparation of tools which has been demonstrated to be durable for more than 66.000 replications in injection moulding processes without loss of surface fidelity. The procedure allows surface roughness reduction from approximately 200 nm Ra down to some few nm for high gloss applications, as well as easy transfer of large-area functional nanostructures on complex 3D surfaces.

Three different types of surfaces were investigated: SOG-layered metal surfaces with three different layer thicknesses, one ingot casted and one electro slag remelted material (with hardness level of 950 and 2500 MPa, respectively). The metal surfaces were ground and polished to mirrorlike finishes.

Three circular samples of each type were rubbed against a hard steel ball of 6.35 mm radius on a commercial pin-on-disk tribometer. To resemble the molding process a sliding speed of 2 mm/s and a load of 8 N were chosen. The tests were performed with 5 minutes intervals until the first damage on the surface were observed. In parallel, scratch tests were performed in the same tribometer. The surfaces were measured in-situ by a portable microscope and a stylus, and afterwards by a white light interferometer and scanning electron microscope to evaluate the size of the wear/scratch traces.

The surface type with the longest time to damage and/or smallest wear/scratch traces was considered to be the most durable one.

Keywords
mirror finish, tribometer, ball-on-disk, scratch-test, SOG-layers
National Category
Mechanical Engineering Tribology (Interacting Surfaces including Friction, Lubrication and Wear)
Identifiers
urn:nbn:se:hh:diva-25136 (URN)
Conference
The 16th Nordic Symposium on Tribology - NORDTRIB 2014, Aarhus, Denmark, 10-13 June, 2014
Available from: 2014-04-23 Created: 2014-04-23 Last updated: 2018-01-11Bibliographically approved
Rebeggiani, S. & Rosén, B.-G. (2014). Factors influencing the surface quality of polished tool steels. Surface Topography: Metrology and Properties, 2(3), Article ID 035004.
Open this publication in new window or tab >>Factors influencing the surface quality of polished tool steels
2014 (English)In: Surface Topography: Metrology and Properties, ISSN 2051-672X, Vol. 2, no 3, article id 035004Article in journal (Refereed) Published
Abstract [en]

Today’s demands on surface quality of moulds for injection moulding of plastic components involve no/low defect contents and roughness levels in the nm-range for high gloss applications. Material properties as well as operating conditions influence the mould finish, and thus the final surface of moulded products. This paper focuses on how particle content and different polishing strategies influence final surface qualities of moulds. Visual estimations of polished tool steel samples were combined with non-contact 3D-surface texture analysis in order to correlate traditional assessments to more quantitative methods, and to be able to analyse the surfaces at nanometer-level.

It was found that steels with a lower proportion of particles, like carbides and oxides, gave rise to smoother polished surfaces. In a comparative study of polishers from different polishing shops, it was found that while different surface preparation strategies can lead to similar final roughness, similar preparation techniques can produce high-quality surfaces from different steel grades. However, the non-contact 3D-surface texture analysis showed that not all smooth polished surfaces have desirable functional topographies for injection moulding of glossy plastic components.

Place, publisher, year, edition, pages
Bristol: Institute of Physics Publishing (IOPP), 2014
Keywords
Polishing strategy, tool steels, surface quality, high gloss appearance
National Category
Manufacturing, Surface and Joining Technology
Identifiers
urn:nbn:se:hh:diva-22174 (URN)2-s2.0-84979198888 (Scopus ID)
Available from: 2013-05-17 Created: 2013-05-17 Last updated: 2017-03-20Bibliographically approved
Rebeggiani, S. & Rosén, B.-G. (2014). Quantitative evaluation of the surface finish of high gloss polished tool steels. Paper presented at 14th International Conference on Metrology and Properties of Engineering Surfaces (Met & Props 2013), Taipei, Taiwan, 17–21 June, 2013. Surface Topography: Metrology and Properties, 2(1), Article ID 014002.
Open this publication in new window or tab >>Quantitative evaluation of the surface finish of high gloss polished tool steels
2014 (English)In: Surface Topography: Metrology and Properties, ISSN 2051-672X, Vol. 2, no 1, article id 014002Article in journal (Refereed) Published
Abstract [en]

Standardized procedures to measure and estimate surface qualities of moulds for injection moulding of plastic components do not exist. Instead, steel producers as well as polishers and mould-users need to rely on master plaques for tactile comparisons and/or their own visual estimations for surface quality controls. This paper presents an overview of various surface evaluation methods of steels, including existing standards and available surface metrology. A new method to evaluate high gloss polished tool steel surfaces, based on a three-dimensional non-contacting measurement technique, is presented. The suggested method is based on defect extraction, and should be useful for both specifications and quality controls. Included defects were found to be quality criteria for polished tool steel surfaces. The surface acceptance levels and defect classification are based on interviews and questionnaires, as well as literature studies and visual estimations of test samples made by experienced polishers. © 2014 IOP Publishing Ltd.

Place, publisher, year, edition, pages
Bristol: Institute of Physics Publishing (IOPP), 2014
Keywords
tool steels, surface characterisation, surface parameters, surface defects
National Category
Manufacturing, Surface and Joining Technology
Identifiers
urn:nbn:se:hh:diva-24329 (URN)10.1088/2051-672X/2/1/014002 (DOI)2-s2.0-84979195167 (Scopus ID)
Conference
14th International Conference on Metrology and Properties of Engineering Surfaces (Met & Props 2013), Taipei, Taiwan, 17–21 June, 2013
Funder
Swedish Foundation for Strategic Research EU, FP7, Seventh Framework Programme
Available from: 2014-01-07 Created: 2014-01-07 Last updated: 2017-03-16Bibliographically approved
Rebeggiani, S., Dimkovski, Z. & Rosén, B.-G. (2014). Traceology for polishing process control. In: R. Leach (Ed.), Conference Proceedings - 14th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2014: . Paper presented at 14th International Conference of the European Society for Precision Engineering & Nanotechnology, Dubrovnik, Croatia, June 2-6, 2014 (pp. 217-220). Bedford: EUSPEN, 1
Open this publication in new window or tab >>Traceology for polishing process control
2014 (English)In: Conference Proceedings - 14th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2014 / [ed] R. Leach, Bedford: EUSPEN , 2014, Vol. 1, p. 217-220Conference paper, Poster (with or without abstract) (Refereed)
Abstract [en]

Final finishing operations of dies and moulds e.g. in the plastic industry, are conventionally performed by manual polishers. With ever increasing demands of shorter lead times and reduced costs, efforts have been made to automate the finishing process. This paper presents the first step towards a built-in surface inspection system for automated polishing processes, designed to indicate when it is time to shift from one preparation step to the next one. It is based on an evaluation procedure for mirror-like steel surfaces, and a characterisation method used to study scratch patterns on cylinder liner surfaces. This method was further developed/adapted to polished steel surfaces. The results showed that scratch width and height were strong indicators for surface quality evaluation.

Place, publisher, year, edition, pages
Bedford: EUSPEN, 2014
Keywords
Polishing strategy, tool steels, surface characterisation, scratch analysis
National Category
Mechanical Engineering
Identifiers
urn:nbn:se:hh:diva-25135 (URN)2-s2.0-84923202114 (Scopus ID)978-095667903-1 (ISBN)
Conference
14th International Conference of the European Society for Precision Engineering & Nanotechnology, Dubrovnik, Croatia, June 2-6, 2014
Available from: 2014-04-23 Created: 2014-04-23 Last updated: 2015-04-17Bibliographically approved
Rebeggiani, S. (2013). On Polishability of Tool Steels. (Doctoral dissertation). Göteborg: Chalmers University of Technology
Open this publication in new window or tab >>On Polishability of Tool Steels
2013 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

One of the world’s fastest growing industries is the plastic industry. Today’s ever increasing demands of high quality products, shorter lead times and reduced costs push development and research forwards. Moulds for plastic injection moulding need to have a functional surface to meet demands on demoulding and wear properties, but also to produce the required final surface quality, which for ‘standard mould qualities’ of high gloss applications means nearly defect free, shiny and smooth mould surfaces with roughness levels in the nm-range.

The aim of this thesis was to develop a metrology framework to quantitatively characterise these mould surfaces in order to gain better understanding of which defect structures are critical at injection moulding, and how these are correlated to material properties and operating conditions in surface preparation of tool steels. In practice this means to capture surface features of some few nm in height/depth up to some hundreds of microns in lateral dimension within insert areas of cm2 and larger. Experiments combining polishers’ experience with steel producers’ as well as non-contact areal texture examinations of surface topography were performed to overcome and link practical skills to academic ones.

Based on areal surface metrology, defect classification and image analysis based surface characterisation, an evaluation procedure for polished tool steel surfaces was developed, initially tested and verified. The suggested method involves descriptions of relevant defect structures and acceptance levels for high gloss polished tool steels in the form of numerical parameter values based on interferometric measurements. It was also concluded that the cleanness of the steels was less important as long as it was kept within reasonable levels; the surface preparation strategy is a major factor influencing the mould surface quality e.g. it was found that a ‘several-step-strategy’ was favourable to avoid defect structures; not all ‘mirror-like’ mould surfaces had desirable topographies for injection moulding, therefore a well-defined mould surface assessment with numerical values describing mould surface quality is necessary to secure effective mould surfaces.

Place, publisher, year, edition, pages
Göteborg: Chalmers University of Technology, 2013. p. 50
Series
Doktorsavhandlingar vid Chalmers tekniska högskola. Ny Serie, ISSN 0346-718X ; 3509
Keywords
tool steels, polishability, surface characterisation, surface texture parameters, high gloss polishing, injection moulding
National Category
Manufacturing, Surface and Joining Technology
Identifiers
urn:nbn:se:hh:diva-22175 (URN)978-91-7385-828-1 (ISBN)
Public defence
2013-04-05, Virtual development laboratory, Chalmers University of Technology, Göteborg, 10:00 (English)
Opponent
Supervisors
Note

Includes pamphlet in Appendix I.

Available from: 2013-11-08 Created: 2013-05-17 Last updated: 2015-01-26Bibliographically approved
Rebeggiani, S. & Rosén, B.-G. (2013). Quantitative evaluation of the surface finish of high gloss polished tool steels. In: Metrology and Properties of Engineering Surfaces, 2013: Proceedings of the 14th International Conference, Taipei, Taiwan, June 17-21, 2013. Paper presented at The 14th International Conference on Metrology and Properties of Engineering Surfaces, Taipei, Taiwan, June 17-21, 2013 (pp. 207-218).
Open this publication in new window or tab >>Quantitative evaluation of the surface finish of high gloss polished tool steels
2013 (English)In: Metrology and Properties of Engineering Surfaces, 2013: Proceedings of the 14th International Conference, Taipei, Taiwan, June 17-21, 2013, 2013, p. 207-218Conference paper, Published paper (Refereed)
Abstract [en]

Standardised procedures to measure and estimate surface qualities of moulds for injection moulding of plastic components do not exist. Instead, steel producers as well as polishers and mould-users need to rely on master plaques for tactile comparisons and/or their own visual estimations for surface quality controls.

This paper presents an overview of various surface evaluation methods of steels, including existing standards and available surface metrology. A new method to evaluate high gloss polished tool steel surfaces, based on a 3D non-contacting measurement technique, is presented. The suggested method is based on defect extraction, and should be useful for both specifications and quality controls. Included defects were found to be quality criteria for polished tool steel surfaces. The surface acceptance levels and defect classification are based on interviews and questionnaires, as well as literature studies and visual estimations of test samples made by experienced polishers.

Keywords
tool steel, surface analysis, characterisation, high gloss, defects
National Category
Manufacturing, Surface and Joining Technology
Identifiers
urn:nbn:se:hh:diva-22171 (URN)
Conference
The 14th International Conference on Metrology and Properties of Engineering Surfaces, Taipei, Taiwan, June 17-21, 2013
Available from: 2013-05-17 Created: 2013-05-17 Last updated: 2015-03-30Bibliographically approved
Rebeggiani, S. & Rosén, B.-G. (2012). A Step-by-Step Analysis of Manual Polishing Sequences. In: Harald Leitner, Regina Kranz, Angelika Tremmel (Ed.), Proceedings of the 9th International Tooling Conference: . Paper presented at Tool 2012 - The 9th International Tooling Conference, 11-14 September, 2012, Leoben, Austria (pp. 317-324).
Open this publication in new window or tab >>A Step-by-Step Analysis of Manual Polishing Sequences
2012 (English)In: Proceedings of the 9th International Tooling Conference / [ed] Harald Leitner, Regina Kranz, Angelika Tremmel, 2012, p. 317-324Conference paper, Oral presentation only (Refereed)
Abstract [en]

Polishing of tool steels for e.g. injection moulding of plastic parts or direct polishing of products is perhaps the most important industrial finishing process today. Polishing is often made manually to ensure the highest quality and nanometre roughness. This study compare steel samples prepared in different companies to study how different polishing sequences affect final surface qualities, i.e. trying to find crucial factors controlling high gloss appearance and defect levels. The samples were prepared in a way that every step of the polishing process could be studied quantitatively at nanometre level using phase shifting- and coherence scanning interferometry. In addition, all samples were qualitatively documented and judged visually by the polishers themselves. It could be concluded that a ‘several-step’ strategy in combination with short polishing time was advantageous. Also, guidelines for tool and abrasive selection is presented suggesting cotton as carrier and diamonds of 1 µm size for more time efficient final polishing.

National Category
Mechanical Engineering
Identifiers
urn:nbn:se:hh:diva-19669 (URN)
Conference
Tool 2012 - The 9th International Tooling Conference, 11-14 September, 2012, Leoben, Austria
Projects
poliMATIC
Funder
Swedish Foundation for Strategic Research EU, FP7, Seventh Framework Programme
Note

Funding: Uddeholms AB, The Swedish Foundation for Strategic Research Fund and ProViking as well as the European Commission Seventh Framework and the poliMATIC project

Available from: 2012-10-04 Created: 2012-09-18 Last updated: 2017-04-21Bibliographically approved
Organisations
Identifiers
ORCID iD: ORCID iD iconorcid.org/0000-0002-9084-819X

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