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<p>Targeted and nondestructive roughness measurement of internal surfaces with complex geometries remains a significant challenge. This paper presents a magnetic-assisted morphological replication method for localized measurement of internal surface topography and roughness. The method enables targeted, nondestructive evaluation of internal surfaces by replicating surface features using a silicone compound. A dedicated tool controlled by an external magnet was developed for localized positioning and material injection. To improve measurement accuracy, a theoretical model was established to analyze the interfacial shear-stress distribution during demolding and to clarify the effect of demolding force on replication fidelity. Experiments were carried out on standard curved workpieces with roughness values ranging from 50&#xa0;nm to 1.6&#xa0;μm under demolding forces of 2–6&#xa0;N. The results demonstrated that the replica can accurately reproduce typical surface features and topography. The highest replication precision was achieved at a demolding force of 3–4&#xa0;N, with a roughness error below 3%, because this range provides a balance between overcoming interfacial adhesion and suppressing replica deformation, whereas excessive force causes unstable separation and morphology distortion. The method was further verified on additively manufactured tubes, where topography and roughness changes before and after polishing were successfully captured. These results indicate that controlling demolding-induced stress concentration is critical for preserving replication fidelity and demonstrate the feasibility of the proposed method for localized, nondestructive characterization of internal surfaces.</p>

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A surface roughness measurement method for internal surface based on magnetic-assisted morphological replication

  • 期刊论文

  • 发表日期：

    2026年8月4日

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  • Qin Pu,
  • Guo Xiaoguang,
  • Li Qikai,
  • Li Linguang,
  • Chen Junjie,
  • Liu Jun,
  • Fang Yuanyuan

摘要

Targeted and nondestructive roughness measurement of internal surfaces with complex geometries remains a significant challenge. This paper presents a magnetic-assisted morphological replication method for localized measurement of internal surface topography and roughness. The method enables targeted, nondestructive evaluation of internal surfaces by replicating surface features using a silicone compound. A dedicated tool controlled by an external magnet was developed for localized positioning and material injection. To improve measurement accuracy, a theoretical model was established to analyze the interfacial shear-stress distribution during demolding and to clarify the effect of demolding force on replication fidelity. Experiments were carried out on standard curved workpieces with roughness values ranging from 50 nm to 1.6 μm under demolding forces of 2–6 N. The results demonstrated that the replica can accurately reproduce typical surface features and topography. The highest replication precision was achieved at a demolding force of 3–4 N, with a roughness error below 3%, because this range provides a balance between overcoming interfacial adhesion and suppressing replica deformation, whereas excessive force causes unstable separation and morphology distortion. The method was further verified on additively manufactured tubes, where topography and roughness changes before and after polishing were successfully captured. These results indicate that controlling demolding-induced stress concentration is critical for preserving replication fidelity and demonstrate the feasibility of the proposed method for localized, nondestructive characterization of internal surfaces.