CONFOCAL LASER SCANNING MICROSCOPY FOR ...18 Int. J. Mech. Eng. & Rob. Res. 2012 Krzysztof Nadolny...

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Int. J. Mech. Eng. & Rob. Res. 2012 Krzysztof Nadolny and Wojciech Kaplonek, 2012

CONFOCAL LASER SCANNING MICROSCOPYFOR CHARACTERISATION OF SURFACE

MICRODISCONTINUITIES OF VITRIFIEDBONDED ABRASIVE TOOLS

Krzysztof Nadolny1* and Wojciech Kaplonek1

*Corresponding Author: Krzysztof Nadolny,[email protected]

Confocal laser scanning microscopy is a relatively new, extremely dynamic and rapidly developingvariation of classical confocal microscopy. Recently, within the technical disciplines related tomechanical engineering and material sciences, an increasing interest in this technique hasbeen observed. Modern, highly-efficient, automated machining processes. Often make use ofgrinding wheels with vitrified bond. When such an abrasive tool is in operation, its active surfacebecomes worn and numerous defects appear, which are highly disadvantageous to the machiningprocess. It is therefore necessary to have a precise assessment of the grinding wheel surface.This article demonstrates that such an assessment can be carried out using an advancedconfocal laser scanning microscopy technique. The 3D laser measuring microscope LEXTOLS4000 by Olympus, utilised in this work, enabled the precise measuring of ceramic grindingwheels with a technical designation 1-352010-CrA/F80J7V and visible microdiscontinuitiesshaped with an abrasive water-jet. An analysis of the measurement data obtained was carriedout using OLS4000 2.1 and TalyMap Platinum 5.0 software. The results of this data included 2Dsurface images and maps, 2D profiles as well as 3D surface topographies with calculatedparameters. These results also prove the high effectiveness and usability of, both, the experimentsrealized and the measurement method proposed. This method might complement, or extend,other methods that may be used in the diagnosis of abrasive tools.

Keywords: Confocal laser scanning microscopy, Microdiscontinuities, Pink fused alumina,Vitrified bonded abrasive tools, Grinding wheels

INTRODUCTIONSearching for better and more effective waysof assessing the surfaces of abrasive tools,

ISSN 2278 – 0149 www.ijmerr.comVol. 1, No. 1, April 2012

© 2012 IJMERR. All Rights Reserved

Int. J. Mech. Eng. & Rob. Res. 2012

1 Department of Production Engineering, Faculty of Mechanical Engineering, Koszalin University of Technology, Raclawicka 15-17,75-620 Koszalin, Poland.

scientists and constructors of measuringsystems have been trying to adapt solutionsthat were primarily designed for other

Research Paper

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purposes and used in different areas ofscience and technology. Examples of suchsolutions can be found in the advancedmethods of non-invasive imaging related tonano- and micro-computed tomography (CT)(Favretto, 2007; Midgley et al., 2007; Cierniak,2011; and Surhone et al., 2011), whichoriginated within, and are derived from, theclassical computed tomography (Hsieh, 2003;Buzug, 2008; and Kalender, 2011) used indiagnostics of the human body. Using suchclassical methods in modern measuringtechnique has a far wider scope. For severalyears there has been an appreciable increasein the interest shown toward methods that useconfocal microscopy (Conn, 2010), thus far,related mainly with the biological and medicalsciences (Pawley, 2006; and Price andJerome, 2011). This increased interest is asa direct result of the improved possibilities toobtain contour images for subsequent sectionsand to generate a 3D image of the examinedobject’s surface, as well as to achieve highquality and high resolution image data withrelatively short acquisition and processingtime. From the point of view of imaging,confocal microscopy successfully fills the gapbetween the conventional wide-field lightmicroscopy and Scanning ElectronMicroscopy (SEM), which makes it highlyadvantageous, offering great applicationpossibilities.

One of the modern variations of classicalconfocal microscopy is Confocal LaserScanning Microscopy (CLSM) (Claxton et al.,2010; and Miller et al., 2010). This techniquewas developed in the early 1980s and the term“confocal” was first used in a work (Brakenhoff,1979). The first commercial laser microscope

entered the market in 1987 (Amos and White,2003; and Jones et al., 2005). Today manyinternational corporations within themeasurement industry (e.g., Keyence, Leica,Olympus, Nikon, Carl Zeiss) manufacturemicroscopes of this type.

CLSM is the next step in the developmentof confocal microscopy techniques, whichstarted with M. Minsky of Harvard Universitypatenting a double-focusing stage scanningmicroscopy in 1957 (Minsky, 1957; Minsky1988; and Clarke and Eberhardt, 2002).Modern CLSM, based on Minsky’s idea, usesnumerous modern solutions from the fields ofoptoelectronics, microelectronics andcomputer science. These include stablemonochromatic laser light sources of greatpower, highly-efficient systems with scanningmirrors, high-capacity optical fibers, thin-layered dielectric coatings and new types ofdetectors, whose application has resulted innoise reduction. Combined with rapidlydeveloping computer technology (a few-hundred times growth in the calculation powerof computers, for example), the perfection ofimage display methods, new technologies forstoring vast amounts of data and thedevelopment of new algorithms for digitalimage processing, the scope of fields andapplications in which CLSM can be used hasbroadened significantly (Mahmoud et al.,2003; Chen et al., 2006; Evans and Donahue,2008; and Miao, 2011).

In this work the Authors considered thepossibility of using the CLSM technique incharacterizing surface microdiscontinuities ofabrasive tools made from PFA abrasive grainsand vitrified bond. Microdiscontinuities arelocal discontinuities in the surface structure of

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the abrasive tool that do not alter itsmacrogeometry. They usually adopt the formof grooves and pits with a regular lay-out. Theymay be shaped in special dressing procedures(Plichta and Bil, 1992; and Nadolny andKaplonek, 2012) or by using high-pressure/abrasive water-jets, for example. Applicationof grinding wheels with active surfacemicrodiscontinuities influences the distributionof thermal-mechanical energy within thegrinding zone in a positive way and contributesto better thermal regulation, wear product andmachined material chip removal, as well asmore efficient coolant delivery (Plichta and Bil,1992). An advanced 3D laser microscopeLEXT OLS4000 by Olympus was used duringthe experiments.

MATERIALS AND METHODSThe main goal of the experiments carried out,that are described in this paper, was to analysethe possibility of using the CLSM technique inmeasuring surface microdiscontinuities ofabrasive tools. The experiments were realized

according to the schedule outlined below, andwhich included four steps:

Step 1: Choice and preparation of samplesfor testing.

Step 2: Shaping the discontinuities on theGrinding Wheel Active Surface(GWAS).

Step 3: Measuring the surface topography ofareas on the grinding wheels withvisible microdiscontinuities.

Step 4: Analysis and interpretation of themeasurement data obtained.

During the experiments a set of 5 sampleswere used, all in the form of small ceramicgrinding wheels (1 referential grinding wheel+ 4 grinding wheels with shapedmicrodiscontinuities) with the technicaldesignation 1-352010-CrA/F80J7V. All ofthe grinding wheels (marked: R – referential,7, 12, 16 and 46) were made from PFA,provided by Graystar LLC (USA), by theDivision of Fundamentals of Materials Scienceat the Institute of Mechatronics,

Name Pink Fused Alumina

Synonyms Chromium (Pink) Fused Alumina, Pink Fused Aluminum Oxide,Pink FA, Alodur Pink, CrA

Chemical name Chromium Fused Aluminum Oxide

Basic minerals -Al2O

3

Chemical composition andpercentage of elements* Al2O

3 (99.52%), Fe

2O

3 (0.05%), Na

2O (0.18%),Cr

2O

3 (0.25%)

Crystal size (m) 600-1400

Grain sizes F80**

Melting point 2050 °C

True density (g/cm³) 3.90

Bulk density (g/cm²) 1.5-1.95

Knoop hardness (Kg/mm²) 2200-2300

Table 1: General Characteristics of PFA

Note: * Chemical composition for low chromium grains, * according to FEPA 42-1:2006, ANSI B74.12 and ISO 8486-1:1996 standards.

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Nanotechnology and Vacuum Technique, withinKoszalin University of Technology. The generalcharacteristics of the abrasive used is

presented in Table 1, while the characteristicsof the small ceramic grinding wheels used inthe measurements are included in Table 2.

Technical designation 1-352010-CrA/F80J7V

Grinding wheel type 1 – flat grinding wheel

Dimensions External diameter 35 mm; Height 20 mm; Internal diameter 10 mm

Abrasive grain type Pink Fused Alumina (CrA)

Abrasive grain fracture 80

Hardness class J

Structure No. 7

Volume of grains 48%

Volume of bond 10%

Volume of pores 42%

Bond Vitrified (amorphous glass bond)

Modifications Microdiscontinuities shaped on the grinding wheel active surface

Table 2: General Characteristics of Grinding Wheels Used in the Experiments

To obtain the surface microdiscontinuitiesa hydro-jetting process was used on all thesamples, except the referential sample. TheOMAX® 55100 JetMachining Center by Omax(USA), designed for cutting with a water/abrasive water jet, was used for this purpose.In the case of the abrasive water-jet, anabrasive, commercially named Indian Garnetand produced by Opta Minerals Inc. (Canada),was used.

Three microdiscontinuities in the form ofgrooves were shaped on the active surface ofeach sample. The depth of the jet input for thefirst groove was 0.563 mm. Each subsequentinput was a doubled value of the previous one,and was respectively: 1.126 mm and 1.689 mm.The groove shaping time was constant, lasting5 seconds. The conditions and parameters forthe process of shaping the surfacemicrodiscontinuities with a water-jet and a

1 R – – – – – –

2 7 Abrasive IndianWater-Jet Garnet 80* 0.355 0.762 0.336 366.801**

3 12 Water-Jet – 0.355 0.762 0.336 366.801**

4 16 Abrasive IndianWater-Jet Garnet 80* 0.355 0.762 0.336 124.105***

5 46 Water-Jet – 0.355 0.762 0.336 124.105***

Table 3: Conditions and Parameters of the Abrasive Water-Jetand Water-Jet Processing

SampleDesignation Processing

Type ofAbrasive

Jewel (Orifice)Diameter (mm)

Mixing TubeDiameter (mm)

Abrasive FlowRate (Kg/min)

Pressure(MPa)Lp.

Note: * Grit size: 80, ** pressure at nozzle in high pressure mode, *** pressure at nozzle in low pressure mode.

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abrasive water-jet are presented in Table 3, whileFigure 1 depicts the general view of the sample

and the way in which the microdiscontinuitieswere shaped on its active surface.

When the process of shapingmicrodiscontinuities on the GWAS wascompleted, they were thoroughly assessed.An advanced 3D laser measuring

microscope, LEXT OLS4000 by Olympus(Japan), was used for this purpose. Ageneral view of the microscope is presentedin Figure 2.

Figure 2: The Advanced 3D Laser Measuring Microscope LEXT OLS4000 Producedby Olympus, Which was Used During the Experiments Conducted

Figure 1: The Process of Hydro-Jetting Samples, for the Obtaining of SurfaceMicrodiscontinuities (a) General View of 1-352010-CrA/F80J7V

Grinding Wheel, (b) Diagram Showing the Way in Which the Microdiscontinuities wereForming on the Surface of the Grinding Wheel, and (c) Sample with ShapedMicrodiscontinuities Fixed in Holder of OMAX® 55100 JetMachining Center

GrindingWheel

Endpoint

Abrasive NozzleMotion Path

StartingPoint

0.5

mm

0.5

mm

(b)

(a)

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The advanced 3D laser measuringmicroscope LEXT, enabled the acquisition ofimages of the examined abrasive toolssurfaces in two modes – microscopic andconfocal one.

In the microscopic mode the examinedsample was illuminated with light of awavelength ranged 400-700 nm. Anelectroluminescent diode (LED), with 30 mWof power, was the light source. Fourobservation techniques were available in thismode: brightfield, darkfield, simple polarizationand Differential Interference Contrast (DIC).

The operation of LEXT OLS4000 in theconfocal mode consisted in generating animage on the basis of light reflection from thediscrete focal plane. The light, creating animage with different focusing depth, waseliminated using the double confocal pinholeaperture. In this mode the microscope used alight beam with wavelength = 405 nm (violet),and the light source was a LED, with 120 mWof power. Obtaining a spatial mapping of theexamined object’s surface entailed its precisescanning, point by point on axes x-y. Thisprocess was realized by a special scannerpatented by Olympus. The scanner used aMicro Electro-Mechanical System (MEMS).The images were acquired using a system oftwo photomultipliers, with average (standard)and high sensitivity. Such a system enabledproper amplification of the optical signal.Therefore it allowed for measuring the surfacesof elements with a low reflection coefficient andlarge surface slope angle, up to 85 degrees.The motorized revolving nosepiece includeda set of 5 microscopic lenses with variousmagnification ranges (5, 10, 20, 50,100). The maximum magnification that could

have been obtained was 17280. Thesamples were placed on a motorized stagethat allowed for precise realization ofdisplacement on axes x-y (range: 100 mm)and axis z (range: 10 mm).

Regardless of the image acquisition mode,image processing and analysis was carriedout using the dedicated OLS4000 2.1software, provided by the microscopeproducer. The software offered numeroususeful functions that proved helpful in theanalysis of the abrasive tools surfaces. Thesewere functions connected with: the measuringof geometrical parameters, quantitativeanalysis, detection of edges and surfaceroughness measurements. In this last casethe program allowed for determination of over80 surface roughness parameters, includingamplitude, functional and volumetric ones.OLS4000 2.1 was supported with TalyMapPlatinum 5.0 software, using MountainsTechnology™ by Digital Surf (France).

RESULTS AND DISCUSSIONThe results of the completed experiments andanalyses were presented using the examplesof three registered microtopographiesobtained from the GWAS: the referentialgrinding wheel (R) and two grinding wheelswith shaped microdiscontinuities (No. 7 andNo. 46). The parameters of microtopographiesregistered using a 3D laser measuringmicroscope LEXT OLS4000, for selectedsamples, are presented in Table 4. All of themeasurements were taken using amicroscopic lens with designation MPLFLN,made by Olympus, whose characteristics aredepicted in Table 5. The measuring time wasvariable and lasted from a few to a few dozen

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minutes (particularly when including the imagestitching procedure).

Figure 3 presents selected views, analysesand parameters of the referential grindingwheel surface texture (R). The top part ofFigure 3 shows the real image of a surfacesized 7.189 7.149 mm and acquired usinga brightfield technique in the optical mode,along with a 3D map sized 7.189 7.149 1.430 mm obtained in the confocal mode. Theimages were acquired using OLS4000 2.1software. Under the above-mentioned imagesthe corresponding results obtained usingTalyMap Platinum 5.0 software are presented.They include: a 2D surface map of the GWAS,a 2D profile and a 3D surface topography ofthe GWAS with selected parameters.

When analyzing the images and mapsobtained the relative uniformity of the toolactive surface, with visible abrasive grainedges of PFA in vitrified bond, can beobserved. As the grinding wheel appeared tohave no shaped microdiscontinuities, the totalheight of the leveled surface measured, wasSt = 0.601 mm, which adhered to the technicalcharacteristics of the grinding wheel.

Figure 4 presents collected results forgrinding wheel No. 7. In this case themicrodiscontinuities were shaped using theabrasive water-jet, with a working pressureof 366.801 MPa. A fragment, sized 15.9 4.72 1.53 mm, was extracted from theacquired grinding wheel, real image sized23.300 4.760 2.380 mm. This fragmentis presented in the form of a 3D surfacetopography for which the values of theselected amplitude (Sa, St), hybrid (Sdr) andspatial (Sds) parameters were determined inaccordance with (Stout et al., 1993). 3Dsurface topography was also used indetermining a single 2D profile, which allowedfor precise analysis of the microdiscontinuityshaping. As in the case of 3D surfacetopography, the values of the selected 2Dparameters were determined (Ra, Rq, Rp,Rv, Rt, Rsk and Rku). Geometrical analysisconnected with the determination of themaximum depth volume and surface area ofthe obtained microdiscontinuities, was alsocarried out.

Figure 5 presents analogical results of theanalyses for grinding wheel No. 46, in which

Designation Producer Type of Objective Lens Mag. NA WD (mm) FN (mm) Imm.

MPLFLN Olympus M Plan SemiApochromat 5 0.15 20.0 26.5 Dry

Table 5: Parameters of MPLFLN Objective Lens

Note: Mag. – Magnification; NA – Numerical Aperture; WD – Working Distance; FN – Field Number; and Imm. – Multi-immersion

Table 4: Parameters of Image Acquisition from the Sample Used in Experiments

SampleDesignation

Scanning ModeImage Size

(pixels)Image Size

(mm)Type of

Objective LensZoomLp.

Note: * using image stitching procedure.

1 R

XYZ Fast Scan + Color

2868 2852 7.189 7.149

MPLFLN 12 7 5466 1116 23.385 4.776*

3 46 5489 1602 16.438 4.798*

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Figure 3: The Collected Results from the Experiment Carried Out for ReferenceSample (R), Performed Using the 3D Laser Measuring Microscope LEXT OLS4000

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Figure 4: The Collected Results from the Experiment Carried Out on Sample No. 7,Performed Using the 3D Laser Measuring Microscope LEXT OLS4000

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Figure 5: The Collected Results from the Experiment Carried Out for Sample No. 46,Performed Using the 3D Laser Measuring Microscope LEXT OLS4000

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discontinuities were shaped with a low workingpressure (124.105 MPa), without the use ofabrasives.

The greater energy of the abrasive water-jet used in the case of grinding wheel No. 7,resulted in shaping discontinuitiescharacterized by a 1.75 (the smallestdiscontinuity) to a 5.31 (the biggestdiscontinuity) times bigger cross-sectionalarea, when compared to grinding wheelNo. 46. The discontinuity depth resultedmostly from the position of the machininghead and was not considerably different inboth cases. The largest recorded differencewas approximately 37% in the case of thedeepest microdiscontinuity. On the otherhand, the microdiscontinuities widths arediametrically opposed. In the case of thegrinding wheel shaped with a high-pressureabrasive water-jet (Figure 4), the

microdiscontinuity width ranged fromapproximately 4.42 to 1.46 times greater thanthe width of the microdiscontinuities shapedwith the water-jet with a pressure of 124.105MPa (Figure 5). Shaping microdiscontinuitieson the GWAS led to an increase in the numberof free intergranular spaces, as well as aconsiderable increase in the total height ofthe unevenness of the obtained surface. In thecase of the referential grinding wheel thevalue of the St parameter was 0.601 mm,while in the case of grinding wheel No. 7St = 1.541, and with grinding wheel No. 46St = 1.390. This translates to over a two-foldincrease of this parameter (256% for grindingwheel No. 7 and 231% for grinding wheelNo. 46). A comparison of the obtainedmeasurement results for all of the examinedsamples is presented, in the form ofdiagrams, in Figure 6.

Figure 6: The Collected Results for the Measurements Pertaining to the GeometricalParameters of the Microdiscontinuities for All Tested Samples

GrindingWheelNo. 7

GrindingWheelNo. 12

GrindingWheelNo. 16

GrindingWheelNo. 46

Microdiscontinuity No. 1



1.8

1.6

1.4

1.2

1.0

0.8

0.6

0.4

0.2

0

Ma

xim

um

De

pth

(m

m)

(a) Maximum Depth

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Having analyzed the measurement resultsobtained, it may be concluded that a changeof such high-energy abrasive water-jetparameters, allows for effective steering, with

the additional pressure and participation of theabrasives, which results in an improvedremoval process when shaping the GWASwith PFA grains and vitrified bond. By

Figure 6 (Cont.)

GrindingWheelNo. 7

GrindingWheelNo. 12

GrindingWheelNo. 16

GrindingWheelNo. 46




5.0

4.5

4.0

3.0

2.5

2.0

1.5

1.0

0.5

0

Ma

xim

um

Wid

th (

mm

)

(b) Maximum Width

3.5

GrindingWheelNo. 7

GrindingWheelNo. 12

GrindingWheelNo. 16

GrindingWheelNo. 46




1.6

1.4

1.2

1.0

0.8

0.6

0.4

0.2

0

Are

a o

f th

e H

ole

(m

m2 )

(c) Area of the Hole

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maintaining constant machining time grindingwheel discontinuities of various width andcross- sectional area can be obtained. Thesegeometrical features of the discontinuities areof decisive functional meaning, as the volumeof the additional shaped intergranular spaces,whose presence influences the grindingprocess in a positive way, is contingent uponthem. A comparison of the width value andareas of the discontinuities shaped with thewater-jet and the abrasive water-jet, provesdecisively that the addition of abrasives to thewater-jet exerted the greatest influence upontheir geometry (Figures 6b and 6c).

The experiment results obtained (Figures 3-5)also prove the high usability of the CLSM asa measurement technique in the assessmentof abrasive tools surfaces, modified in theabove-described ways.

CONCLUSIONThe article presents possible applications ofCLSM in the assessment of the condition ofthe GWAS with PFA grains and vitrified bond.The grinding wheels examined underwent theprocedure of shaping microdiscontinuitiesusing high-pressure abrasive water-jets withvarious technological parameters. The resultsobtained from measurement of the GWAS inthis manner, confirmed the high usability of themeasurement method described.

The obtained surface microtopographiesallowed for a thorough visual and parametricalanalysis of the assessed grinding wheels. Onthe basis of this analysis, it was concluded thatthe application of a high-energy abrasivewater-jet (with a pressure of 366.801 MPa)facilitated shaping discontinuities of greaterwidth and cross- sectional area than in the case

of a low-pressure water-jet (with a pressure of124.105 MPa).

The CLSM technique may constitute aninteresting alternative for methods currentlyused in abrasive tools diagnostics, such asstylus and optical profilometry, as well asinterference microscopy. It may alsocomplement the above methods as a referentialmethod. In years to come Confocal should beexpected to become one of the most rapidlydeveloping and exceptionally dynamic opticalmeasurement techniques. Already today thereare numerous science and technology areaswhere it is used extensively.

ACKNOWLEDGMENTPart of this work was supported by the PolishMinistry of Science and Higher Educationunder Grant No. N503 214837. The Authorswould like to thank Mrs. Daniela Herman, D.Sc,Ph.D., from the Division of Fundamentals ofMaterials Science of the Institute ofMechatronics, Nanotechnology and VacuumTechnique at Koszalin University ofTechnology, for preparing the grinding wheelsfor tests, Mr. Michal Bielecki, M.Sc., B.Sc., fromUnconventional HydroJetting TechnologyCenter at Koszalin University of Technology,for shaping of the microdiscontinuities on theGWAS, as well as Mr. Robert Tomkowski,M.Sc., B.Sc., from the Laboratory of Micro- andNanoengineering at Koszalin University ofTechnology, for the optical m measurement ofthe test samples surface topographies.

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Confocal Scanning Laser Microscope”,Transactions of Nonferrous Metals Societyin China, Vol. 21, No. 2, pp. 236-242.

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NOMENCLATURE

Ra Arithmetic mean deviation of profile, mm

Rq Root mean square deviation of profile, mm

Rp Maximum profile peak height, mm

Rv Maximum profile valley depth, mm

Rt Total height of profile, mm

R z Maximum height of profile, mm

Rsk Skewness of profile, –

Rku Kurtosis of profile, –

Sa Arithmetic mean height, mm

St Total height of the surface, mm

Sdr Developed interfacial area ratio, %

Sds Density of summits of the surface, 1/mm2

ABBREVIATIONS

ANSI American National Standards Institute

CLSM Confocal Laser Scanning Microscope

FEPA Federation of European Producers of Abrasives

GWAS Grinding Wheel Active Surface

ISO International Organization for Standardization

PFA Pink Fused Alumina

APPENDIX

CONFOCAL LASER SCANNING MICROSCOPY FOR ...18 Int. J. Mech. Eng. & Rob. Res. 2012 Krzysztof Nadolny...

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