ENGINEERING - COnnecting REpositories · 2017. 10. 13. · Dr. Cheng Lai Hoong (Universiti Sains...

ESTEEM Academic Journal Vol. 9, No. 1, June 2013

p-ISSN 1675-7939; e-ISSN 2289-4934 © 2013 Universiti Teknologi MARA (Pulau Pinang)

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EDITORIAL BOARD ESTEEM ACADEMIC JOURNAL VOLUME 9, NUMBER 1, JUNE 2013 Universiti Teknologi MARA (Pulau Pinang)

ENGINEERING ADVISORS Tan Sri Prof. Ir. Dr. Sahol Hamid Bin Abu Bakar, FASc Assoc. Prof. Mohd. Zaki Abdullah PANEL OF REVIEWERS Prof. Ahmad Izani Md. Ismail (Universiti Sains Malaysia) Assoc. Prof. Dr. Farid Che Ghazali (Universiti Sains Malaysia) Assoc. Prof. Dr. Jaafar Jantan (Universiti Teknologi MARA Shah Alam) Dr. Ahmad Rafizan Mohamad Daud (Universiti Teknologi MARA Shah Alam) Dr. Bakhtiar Md. Shaari (Politeknik Sultan Haji Ahmad Shah) Dr. Cheng Lai Hoong (Universiti Sains Malaysia) Dr. Koay Mei Hyie (Universiti Teknologi MARA Shah Alam) Dr. Lau Tze Liang (Universiti Sains Malaysia) Dr. Mohamad Fahmi B. Hussin (Universiti Teknologi MARA Shah Alam) CHIEF EDITOR Dr. Chang Siu Hua MANAGING EDITOR Maryam Farooqi LANGUAGE EDITORS Dr. Soo Kum Yoke Kamalanathan M. Ramakrishnan Zaira Mohd Nor

http://uppp.uitm.edu.my/



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FOREWORD It is our great pleasure to present the ninth volume and first issue of the ESTEEM Academic Journal UiTM (Pulau Pinang): a peer-refereed academic journal devoted to all engineering disciplines. Since the beginning of the year, a number of articles have been sent to us, some of which are still under review in their first or second phase and the first five of them are being published now. Article submissions came from UiTM campuses across the country, with topics covering most, if not all, of the subfields of electrical, mechanical, civil and chemical engineerings. We celebrate our good fortune in having a strong group of people who created the opportunity for this volume to be born and who made it happen. First and foremost, we would like to extend our sincere appreciation and utmost gratitude to Associate Professor Mohd Zaki Abdullah, Rector of UiTM (Pulau Pinang), Associate Professor Ir. Bahardin Baharom, Deputy Rector of Academic Affairs and Dr. Mohd Subri Tahir, Deputy Rector of Research, Industry, Community & Alumni Network for their unstinting support towards the successful publication of this volume. Not to be forgotten also are the constructive and invaluable comments given by the eminent panels of external reviewers and language editors who have worked assiduously towards ensuring that all the articles published in this volume are of the highest quality. A special acknowledgement is dedicated to all committees, publication department, and many other relevant parties for making this volume a success. Their affective commitment and close cooperation have facilitated the realization of this volume. Last but not least, our greatest thanks go to all the authors for their interest in publishing their work with us. Their manuscripts are an expression of their commitment towards research and development which, in due course, would benefit the local, national and international communities. Hence, we would like to extend our warm invitation to all researchers who are actively involved in the field of engineering to publish their work with us. Dr. Chang Siu Hua Chief Editor ESTEEM Academic Journal Vol. 9, No. 1 (2013) (Engineering)



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CONTENTS OF JOURNAL 1. Fabrication and Characterization of Flame Retardant 4 and

Polydimethylsiloxane as Substrates for a Label-Free DNA Sensor Irni Hamiza Hamzah, Emilia Noorsal, Mohammad Nizam Ibrahim, Asrulnizam Abd Manaf and Othman Sidek

1

2. Determination of the Young’s Modulus of Miniaturized Cantilever by

Measuring Micro-deflection Using the Phase-shift Shadow Moiré Method Lim Jiunn Hsuh, Mani Maran Ratnam, Ong Jiunn Chit and Chiang Ee Pin

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3. New and Old Buildings Microenvironment – An Indoor Air Quality

Study Siti Fatimah Ghazali, Suhaily Amran, Lailatul Akmar Mat Nor, Siti Nazrina Camalxaman and Maimunah Mustakim

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4. Online OBE-CQI Tool for Engineering Programmes

Mohaiyedin Idris, Mohd Affandi Shafie and Liaw Shun Chone

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5. Development of Fuel Additives to Enhance the Performances of Four-

Cylinder Spark-Ignition Engine Mohd Khaizalfitri Mhd Yaakob, Mohd Azahar Mohd Ariff, Mahamad Hisyam Mahamad Basri, Sharzali Che Mat and Azmi Husin

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https://www.dropbox.com/s/2pfrpujr34gkudz/V9N1A1F.pdfhttps://www.dropbox.com/s/oxqbc4zpcc3lznc/Fabrication and Characterizatio - Irni Hamiza Hamzah, Emilia Noor.epubhttps://www.dropbox.com/s/y57m51sxkns8pad/V9N1A2F.pdfhttps://www.dropbox.com/s/fy2onhz1sbbnay4/Determination of the Young's Mo - Lim Jiunn Hsuh, Mani Maran Ratn.epubhttps://www.dropbox.com/s/5uhnez0ehz4xqc6/V9N1A3F.pdfhttps://www.dropbox.com/s/ilsqx9nejqlbxag/New and Old Buildings Microenvi - Siti Fatimah Ghazali, Suhaily A.epubhttps://www.dropbox.com/s/y1267eeujj77at3/V9N1A4F.pdfhttps://www.dropbox.com/s/cgxldds4a8k5uwh/Online OBE-CQI Tool for Enginee - Mohaiyedin Idris, Mohd Affandi .epubhttps://www.dropbox.com/s/4wqctcgkrg0szir/V9N1A5F.pdfhttps://www.dropbox.com/s/6zqbd624qlsjgxa/Development of Fuel Additives t - Mohd Khaizalfitri Mhd Yaakob, M.epub

ESTEEM Academic Journal Vol. 9, No. 1, June 2013, 12-23


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DETERMINATION OF THE YOUNG’S MODULUS OF MINIATURIZED CANTILEVER BY MEASURING MICRO-DEFLECTION USING THE PHASE-SHIFT

SHADOW MOIRÉ METHOD

Lim Jiunn Hsuh1, Mani Maran Ratnam2, Ong Jiunn Chit3 and Chiang Ee Pin4

1,3,4Faculty of Mechanical Engineering, Universiti Teknologi MARA (Pulau Pinang), Jalan Permatang Pauh, 13500 Permatang Pauh, Pulau Pinang, Malaysia.

2Schools of Mechanical Engineering, Engineering Campus, Universiti Sains Malaysia (USM), 14300 Nibong Tebal, Pulau Pinang, Malaysia.

[email protected]; [email protected]; [email protected]; [email protected]

ABSTRACT

This paper presents a measurement for micro-deflection of miniaturized cantilever using phase-shift shadow moiré (PSSM) method and determines the Young’s modulus of the cantilever material. The measurement equipment is calibrated by measuring and comparing the known surface profile of a cylinder with the results from PSSM. The calibration shows that PSSM technique applied has the measurement error of 6 µm. The PSSM method is then applied to measure the micro-deflection of a miniaturized cantilever. The cantilever has the dimensions of 6.49 mm x 0.96 mm x 0.16 mm and the Young’s modulus is unknown. The Young’s modulus of the cantilever material is estimated from theory by using the measured deflection profile. Both the measured and estimated deflection profile are plotted to check for any discrepancy. The comparison shows that the measured deflection profile is similar to the estimated deflection profile. Therefore, the Young’s modulus of the cantilever is estimated to be 60.65 GPa with the uncertainty of ±2.66GPa. The experiment presented in this paper shows the procedure and method to measure the deflection of a miniaturized cantilever and estimate the unknown Young’s modulus.

Keywords: Phase-shift shadow moiré (PSSM); Micro-deflection; Young’s modulus.

1. INTRODUCTION

One of the important material property in the analysis of the mechanical behaviour of structural members is the Young’s modulus of the structural members. The Young’s modulus of such structures usually is determined from tensile or bending tests. The displacement data obtained from tensile tests or bending tests are then applied into the theoretical equation to find the Young’s modulus of the structural material. However, the measurements for deflection of the miniaturized structures such as miniaturized cantilevers are almost impossible by using the conventional point-wise contact method to conduct the tensile or



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bending tests. The probe of the conventional measurement device such as coordinate measurement machine (CMM) will impose additional load to the miniaturized cantilever and cause significant measurement error (Lim, Ratnam, Azid, & Mutharasu, 2011). Optical measurement such as holographic, ESPI, shadow moiré and moiré interferometry methods are well known as reliable, accurate, non-contact and non-destructive methods (Lim, Ratnam, Azid, & Mutharasu, 2010; Wang & Tay, 2006). The non-contact feature of optical methods can overcome the above mentioned problem.

The shadow moiré method is a cost effective and versatile optical method. This method has a measurement range of approximately 10 micro-meters to a few centimeters, depending on the pitch of the grating used (Degrieck, Van Paepegem, & Boone, 2001; Lim, Ratnam, & Abdul Khalil, 2003; Wang, Quan, Tay, Reading, & Fang, 2003). The phase-shift technique is an image processing technique to enhance the measurement resolution and is normally integrated into the interferogram analysis techniques (Ratnam, Lim, & Abdul Khalil, 2003; Chen, Chen, Chuang, & Lin, 2004). This research work is to establish the experimental procedure of the phase-shift shadow moire (PSSM) method and apply the method to determine the Young’s modulus of a miniatualized copper cantilever.

2. THEORIES

2.1 Shadow Moiré Method

Figure 1 shows the basic shadow moiré setup. This setup comprises a light source that projects a shadow of a linear reference grating titled at an angle α to the beam direction onto a three-dimensional diffusive object (Kafri & Glatt, 1990). A camera is placed on top of the the grating and the shadow of the reference grating is observed as a distorted grating. The amount of distortion is proportional to h (x , y) tan α , where h (x , y) is the height variation function. To determine the fringe position, the reference grating with the pitch p can be represented by a line grid, which is described by a set of indicial equations as:

(1)

For the shadow grating that is distorted the lines deviate from linearity by an amount h (x , y) tan α , then the equation acquire the form:

(2)

Since both the straight reference grating and the deformed shadow grating are parallel, i.e. the rotation angle between reference and distortion grating is zero, their superposition results is:

(3)

Equation (3) is the result of the superposition of the reference and distorted grating and represents the topographic contour map of the object with a height increment p cotα between successive fringes, l .

y = mp, m = 0, ±1, ±2 …

y + h (x , y) tan α = np, n = 0, ±1, ±2 …

, l = 0, ±1, ±2 … αtan

),( lpyxh =∴



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Figure 1: Setup for Shadow Moiré Technique.

2.2 Phase-shift Technique

The fringe pattern is an image with the dark and white countours. The fringe pattern is a sinusoidal function and is represented by intensity distribution I (x , y) (Malacara, Servin, & Malacara, 1998). This function can be written in a general form as:

(4)

where, a is background intensity variation, b is the modulation strength, φ (x , y) is the phase at origin and α is the phase shift with respect to the origin. The phase φ (x , y) can be measured by many phase detection methods such as least squares phase detection, quadrature phase detection, Fourier description of synchronous phase detection, phase shifting algorithm, spatial carrier phase shifting method, phase lock loop demodulation method and etc (Malacara et al., 1998). Among the method, phase-shifting method is considered as simple and stright forward method to determine the phase φ (x , y).

The Equation (4) has four unknowns i.e. a, b, φ and α. However, only minimum three samples of signal measurements needed to determine the phase φ because the value of term α can be predetermined. In order to solve Equation (4) three values of α are predetermined as 0π, 2 π/3 and 4 π/3. Thus, Equation (4) above can be rewritten as:

(5a)

(5b)

(5c)

Physically, by altering the phase value α in 2π/3 interval, the fringes position is shifted by 1/3 spacing. The intensity distribution of the fringe pattern in a pixel may be represented by a gray scale, which is vary from 0 to 255. In this gray scale, black indicates the value of 0, white indicates the value of 255, and all other gray levels represent intermediate values. By measuring the pixel value at each coordinate in an interferogram and solving the three above mentioned equations, the modulation phase φ ( x , y ) can be determined:

I (x ,y) = a(x ,y) + b(x ,y) cos (φ (x,y) + α)

I1 (x ,y) = a (x ,y) + b (x ,y) cos φ (x ,y)

I2 (x ,y) = a (x ,y) + b (x ,y) cos (φ (x ,y) + 2 π/3)

I3 (x ,y) = a (x ,y) + b (x ,y) cos (φ (x ,y) + 4 π/3)



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(6)

By applying the phase shifting algorithm, the modulation phase φ can be determined. The arctangent function in Equation (6) involved in the phase calculation introduces a discontinuous value of phase φ over the range of -π to π. Therefore, the phase must be adjusted according to the values in numerator and the denominator in the expression of arctangent. After adjustment, the phase has to be unwrapped according to the fringe order number in order to illustrate the actual measurement.

3. MEASUREMENT

3.1 Calibration

A circular cylindrical rod is machined into diameter of 24.00 mm. The rod is then cut into 5 mm thickness specimen, and one of the cutting surface is grained using a piece of fine-sand paper to produce the smooth cutting edge. The specimen is then sprayed by white paint and one of the surfaces of the specimen is measured using profile projector. Next, the same surface is measured again using phase-shift shadow moiré technique. Three images are captured with the phase shifted with 2π/3 interval. The images are then processed using phase-shift algorithm and unwrapping algorithm to find the surface profile. The algorithms are written in MATLAB programming language. The measurement results from the profile projector are compared with the results from PSSM method in order to find the PSSM measurement error. Figure 2 shows the PSSM experimental setup from the cylinder measurement.

Figure 2: Schematic for the PSSM Setup for Cylinder Surface Profile Measurement.

3.2 Micro Deflection Measurement

A mini cantilever of dimension 6.49 mm x 0.96 mm x 0.16 mm is cut into the shape as shown in Figure 3. This cantilever has the unknown Young’s modulus and is soldered on a copper plate to form the fixed. A slot is cut at the free end of the cantilever so that a fine wire can be tightened at the free end and loads can be applied. The free end of the cantilever is loaded

321

231

2)(3tan),(

IIIIIyx−−

−= −φ



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with a weight as shown in Figure 3. The entire cantilever assembly is then placed under the phase shifting shadow moiré setup. Three images are captured and processed using the phase-shift and unwrapping programs.

Figure 3: Schematic of the Copper Cantilever with Unknown Young’s Modulus.

Figure 4: Schematic of the PSSM Setup for Cantilever Deflection Measurement

The profiles before and after loading are calculated. The deflection profile after loading is then subtracted from the profile before loading in order to find the actual deflection. The actual deflection value is than substituted in bending equation to calculate the estimated Young’s modulus of the cantilever.

4. RESULTS AND DISCUSSIONS

4.1 Calibration

Figure 5 shows the original image of the cylinder. The area under investigation that consists of 4 dark fringes is measured by using the 3-steps PSSM technique. Figures 6 (a) to (d) show



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the images with 0 π, 2/3 π and 4/3 π phase shifted respectively, and the phase map after processing. The unwrapped phase that represents the three-dimensional cylinder profile is shown in Figure 6(e). The Figure 6(f) is the comparison of the results from profile projector with the results from optical measurement (curve fitted). After calculating the differences of the measurement between the two methods, the standard deviation of the differences is calculated as 5.87 µm.

Figure 5: The Analysis Area at the Original Image.

Figure 6: (a) 0 π Phase-shifted, (b) 2/3 π Phase-shifted, (c) 4/3 π Phase-shifted and (d) the Wrapped Phase Map.



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Figure 6: (e) The Unwrapped Phase Map that Represents the Cylinder Surface Profile.

Figure 6: (f) The Phase-Shift Shadow Moiré Result Compared with the Profile Projector Result.

4.2 Micro Deflection Measurement

Figure 7 shows image of the miniaturized cantilever after it is loaded with 0.0666N loads. The area of interest is measured using 3-steps PSSM method. The images of 0 π, 2/3 π, 4/3 π phase-shifted and the wrapped phase map after processing are shown in Figures 8(a) to (d). Figure 8(e) shows the unwrapped phase map that represents the deflection profile. Figure 8(f) shows the two-dimensional deflection profile for section A – A after subtract the profile



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before and after loading. After subtraction, the actual deflection profile is plotted in Figure 8(g).

Figure 7: The 0 π Phase Shifted Image of the Cantilever after Loading.

Figure 8: (a) the 0 π Phase Shifted, (b) 2/3 π Phase-Shifted, (c) 4/3 π Phase-Shifted, (d) the Unwrapped Phase Map.



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Figure 8: (e) The Unwrapped Phase Map that Represents the Deflection Profile.

Figure 8: (f) The 2-D Deflection Profile after Subtraction of Profiles before and after Loading.



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Figure 8: (g)The Deflection Profile Obtained from PSSM (after Subtraction) and the Profile Obtained from Estimation, E = 60.65 GPa.

The deflection profile after loading is subtracted from the surface profile before loading to get the actual deflection. In the experiment, the actual deflection is calculated and the deflection at the free end is 297.1 µm.

If the deflection at the free end can be measured accurately, Young’s modulus can be estimated from the bending equation (Khurmi, 1989):

(7)

where, y = deflection at the free end, w = loads, l = length measured from fixed end to free end, E = Young’s modulus and , I = second moment of area. Expend the second moment of area and rearrange the Equation (7),

(8)

where, the b = the width and h = the thickness of the cantilever. The uncertainty of the estimated Young’s modulus can be calculated from the propagation of uncertainty equation (Beckwith, Marangoni, & Lienhard, 2007),

(9)

where, uE = uncertainty of Young’s modulus, w = uncertainty of loads, l = uncertainty of length, y = uncertainty of deflection at free end, b = uncertainty of width, h = uncertainty of thickness.

EIwly

3

3−=

3

34ybh

wlE −=

22222

∂∂

+

∂∂

+

∂∂

+

∂∂

+

∂∂

= hbylwE uhEu

bEu

yEu

lEu

wEu



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The uncertainty of the loads is identified as ±0.0001 N and the uncertainties for all the length measurement are identified as ±2 µm (data from the operation manual provided by the manufacturers). Solving the Equations (8) and (9), the estimated Young’s modulus is 60.65 GPa and the uncertainty of the estimated Young’s modulus is ±2.66 GPa. Figure 8(g) shows the deflection profile plotted by using the estimated value of Young’s modulus, E = 60.65 GPa is similar with the deflection profile measured using PSSM. This comparison shows that the actual measurement is close to the theoretical calculation.

5. CONCLUSIONS

This paper presented the experimental work done on implementing the non-contact PSSM method to measure the micro-deflection and to determine the Young’s modulus of miniaturized cantilever. The PSSM method proposed had been calibrated by comparing the measurement results with other reliable measurement such as profile projector. The profile projector has the standard measurement error of ±2 µm, and therefore can be used as the reference. The PSSM method has the measurement error of ±6 µm. The calibrated instrument is then applied to measure the micro-deflection of a miniaturized cantilever which has the unknown Young’s modulus. The deflection profile is measured and the Young’s modulus has been estimated as 60.65 GPa. The uncertainty of the estimated Young’s modulus is calculated using propagation of uncertainty equation and is found to be ±2.66 GPa.

The comparison of the measured deflection profile with the theoretical calculation shows a close agreement of each other. The experimetal result shows the ability of PSSM method to measure the micro-deflection of a miniaturized cantilever and estimate the corresponding unknown Young’s modulus. The significance of this research work is that the experimetal procedure for measureing the micro-deflection has been established and the Young’s modulus of miniaturized structure is estimated by using this simple PSSM method.

REFERENCES

Beckwith, T. G, Marangoni, R. D., & Lienhard, J. H. (2007). Mechanical Measurement, 6th Edition, Singapore : Pearson Education International.

Chen, K. S., Chen Y. F., Chuang, C. C. & Lin, I. K. (2004). Full-field wafer level thin film stress measurement by phase-stepping shadow moiré. IEEE Transactions on Components and Packing Technologies, 27(3), 594-601. doi: 10.1109/TCAPT.2004.831830

Degrieck, J., Van Paepegem, W., & Boone, P. (2001). Application of digital phase-shift Shadow Moiré to micro deformation measurements of curved surfaces. Optics and Lasers in Engineering, 36, 29-40. doi: http://dx.doi.org/10.1016/S0143-8166(01)00044-6

Kafri, O., & Glatt, I. (1990). The Physics of Moiré Metrology. USA: John Wiley & Sons, Inc.

Khurmi, R. S. (1989). Strength of Material. New Delhi: Chand & Company Ltd.

Lim, J. H., Ratnam, M. M., & Abdul Khalil, H. P. S. (2003). An experimental and finite element analysis of the static deformation of natural fiber-reinforced composite beam.



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Polymer Testing, 22(2), 169 – 177. doi: http://dx.doi.org/10.1016/S0142-9418(02)00066-1

Lim, J. H., Ratnam, M. M., Azid, I. A., & Mutharasu, D. (2010). Deflection measurement and determination of Young's modulus of micro-cantilever using phase-shift shadow moiré method. Experimental Mechanics, 50(7), 1051–1060.

Lim, J. H., Ratnam, M. M., Azid, I. A., & Mutharasu, D. (2011). Determination of Young's modulus of epoxy coated polyethylene micro-cantilever using phase-shift shadow moiré method. Optics and Lasers in Engineering, 49 (11), 1301-1308. doi: http://dx.doi.org/ 10.1016/j. optlaseng . 2011.06.005

Malacara, D., Servin, M., & Malacara, Z. (1998). Interferogram Analysis for Optical Testing. New York: Marcel Dekker Inc.

Ratnam, M. M., Lim, J. H., & Abdul Khalil, H. P. S. (2005). Comparative study of 3-d deformation of a pallet using phase-shift Shadow Moiré and finite element analysis. Experimental Mechanics, 45 (1), 9-17.

Wang S. H., Quan C., Tay, C. J., Reading, I., & Fang, Z. P. (2003). Deformation measurement of MEMS components using optical interferometry. Measurement Science and Technology, 14, 909-915.

Wang, S. H. and Tay, C. J. (2006). Application of an optical interferometer for measuring the surface contour of micro-components. Measurement Science and Technology, 17, 617-625.

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ABSTRACT1. INTRODUCTION2. THEORIES2.1 Shadow Moiré Method2.2 Phase-shift Technique

3. MEASUREMENT3.1 Calibration3.2 Micro Deflection Measurement

4. RESULTS AND DISCUSSIONS4.1 Calibration4.2 Micro Deflection Measurement

5. CONCLUSIONSREFERENCES

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