Friction Reduction of Chrome-Coated Surface with Micro-Dimple Arrays Generated by Electrochemical Micromachining

Chen, Xiaolei; Qu, Ningsong; Hou, Zhibao; Wang, Xiaolei; Zhu, Daiyin

doi:10.1007/s11665-017-2501-5

Cited by 14 publications

(10 citation statements)

References 29 publications

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“…Chen et al [69] had applied the ECM method with TMEMM technic together with a PDMS mask and successfully produce micro dimple array on a cylindrical surface. These studies show improvement in friction coefficient [64,74] and wear [60] with fabricated micro dimples as well as able to produce a different type of micro dimple shapes [63,[60][61]. However, there is still a lack the studies of tribological behavior of ECM produced micro dimples.…”

Section: Electrochemical Machining (Ecm) and Electrical Discharge Machimentioning

confidence: 96%

“…The advantages of ECM are that it lacks residual stresses and heat-affected layer, not having tool wear issues and able for large area machining [59]. However, the main issues of this process are that it requires the texturing work piece to be masked individually which increase the process time and cost [60] and also the quality of individual dimple [61]. Many of the studies recently focus on producing micro dimple array instead of single dimple [62].…”

Section: Electrochemical Machining (Ecm) and Electrical Discharge Machimentioning

confidence: 99%

“…Many of the studies recently focus on producing micro dimple array instead of single dimple [62]. Many technics have emerged such as maskless electrochemical texturing (MECT) [60,63], through-mask electrochemical micromachining (TMEMM) [58,62,[64][65][66][67], using Polydimethylsiloxane (PDMS) mask [59,61,[68][69][70][71], sandwich-like electrochemical micromachining (SLEMM) [72][73] and others [74]. Chen et al [69] had applied the ECM method with TMEMM technic together with a PDMS mask and successfully produce micro dimple array on a cylindrical surface.…”

Section: Electrochemical Machining (Ecm) and Electrical Discharge Machimentioning

confidence: 99%

See 2 more Smart Citations

A Review of Surface Texturing in Internal Combustion Engine Piston Assembly

Azmi¹,

Mahmood²,

Ghani³

et al. 2020

IJIE

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This paper presents a brief review of surface texturing with a focus on piston assembly application. The paper begins with a general discussion on surface texturing and the manufacturing process of micro dimples. Further, it discusses the theory of hydrodynamic lift generation and the effect of parameters of micro dimples texture on the surface-to-surface friction. Finally, the effect of surface texturing on heat transfer is briefly discussed. In pursuits to improve internal combustion engine (ICE) efficiency, tribological improvement of moving surfaces by means of micro surface texturing seems to be one of the way. However, texturing parameters have to be carefully designed as it can cause detrimental effect if the designs are wrong. Studies has shown micro surface texturing at piston ring could reduce friction around 20%-50% compare with un-textured piston ring and also reduce fuel consumption at 4%. Micro Surface texturing could also improve heat transfer between the surfaces to reduce piston slap and lubrication oil temperature. As reports on the surface texturing on friction reduction and heat transfer improvement in piston assembly are relatively scarce, it is suggested that optimization of micro dimple parameters for piston skirt application and its effect on engine tribology and heat transfer characteristics to be further investigated.

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Section: Electrochemical Machining (Ecm) and Electrical Discharge Machimentioning

confidence: 96%

Section: Electrochemical Machining (Ecm) and Electrical Discharge Machimentioning

confidence: 99%

Section: Electrochemical Machining (Ecm) and Electrical Discharge Machimentioning

confidence: 99%

See 1 more Smart Citation

A Review of Surface Texturing in Internal Combustion Engine Piston Assembly

Azmi¹,

Mahmood²,

Ghani³

et al. 2020

IJIE

View full text Add to dashboard Cite

show abstract

“…Lubrication conditions investigated include boundary [24,[30][31][32], mixed [11,27,[33][34][35][36], EHL [14,[37][38][39] and hydrodynamic [6,[40][41][42][43][44][45][46][47][48][49][50][51][52]. Lubrication hypotheses include hydrodynamic [6,7,11,33,40,41,[49][50][51][52][53][54][55][56][57][58][59][60], microrepository for lubricants [41,49,50,55,58,…”

Section: Introductionmentioning

confidence: 99%

A Simple Analysis of Texture-Induced Friction Reduction Based on Surface Roughness Ratio

Xuan

Qiao³

et al. 2021

Tribol Lett

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The effect of surface texture on friction reduction under fluid lubrication has been broadly acknowledged in the tribology community. However, the lack of understanding of the underlying mechanisms remains a challenge for the advancement of textured enhanced lubrication. Numerous models have been proposed, but they are almost all based on the hydrodynamic effect alone and have proven cumbersome, system specific and unreflective of the beneficial secondary lubrication provided by the residual lubricants within the texture. This paper presents a simple analysis of texture induced friction reduction based on the actual liquid-solid interface area and the secondary lubrication hypothesis. A simple model based on the surface roughness ratio (the ratio between the actual and projected solid surface area) of the textured surface was proposed which 1) is simple, intuitive, quantitative and sensitive to texture shape and area fraction; 2) directly reflects proposed secondary lubrication mechanisms; 3) reflects the general data trend in the collected literature. By focusing on the variations of key texture parameters, the proposed model combined with a sampling of independent studies in literature has demonstrated that 1) the effect of increased pit depth-to-diameter ratio (d/D) on friction reduction is most significant between 0.01 and 0.2; 2) further increase in d/D only marginally affects the friction coefficient; 3) texture's area fraction plays a much weaker role than the depth/diameter ratio in friction reduction. By quantitatively isolating the secondary lubrication effects, this model may help to link disparate studies in the literature while providing defensible quantitative insights into texture induced lubrication mechanisms.

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“…The lowest friction coefficient reduction ratio is observed for square dimples at the depth of 20 µm. 18 Higher concentration of electrolyte is not suitable economically and reduces the machining accuracy.…”

Section: Introductionmentioning

confidence: 99%

Influence of electrolytes on surface texture characteristics generated by electrochemical micromachining

Kunar

Mahata

Bhattacharyya

2018

Journal of Micromanufacturing

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Generation of microsurface texture is an important technology for surface engineering that can produce a significant improvement of engineering components in aspects to wear resistance, friction coefficient, load capacities, part lubrication, etc. This research proposes a novel approach of maskless electrochemical micromachining (EMM), which is anodic dissolution based on electrochemical reaction. One reused textured cathode tool with patterned SU-8 2150 mask can fabricate many work samples economically with less time. Maskless EMM set-up with developed EMM cell and vertical crossflow electrolyte supply system is used to generate micro circular patterns on stainless steel (SUS 304) using three different types of electrolytes such as NaCl, NaNO3 and NaCl + NaNO3. The influences of major process parameters such as interelectrode gap (IEG), flow rate, machining time and electrolyte concentration on mean radial overcut and mean machining depth have been investigated using these electrolytes. Out of these three electrolytes, only NaCl + NaNO3 of 20 g l−1 is selected as the best electrolyte with other best parameter settings such as applied voltage of 12 V, duty ratio of 30%, pulse frequency of 5 kHz, flow rate of 3.12 m3 hr−1, IEG of 50 µm and machining time of 3 minutes for generating good textured characteristics with overcut of 27.581 µm and depth of 15.1 µm. Analyses have also been done to investigate the textured characteristics using these electrolytes for acquiring the best parametric combination with suitable electrolyte.

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Friction Reduction of Chrome-Coated Surface with Micro-Dimple Arrays Generated by Electrochemical Micromachining

Cited by 14 publications

References 29 publications

A Review of Surface Texturing in Internal Combustion Engine Piston Assembly

A Review of Surface Texturing in Internal Combustion Engine Piston Assembly

A Simple Analysis of Texture-Induced Friction Reduction Based on Surface Roughness Ratio

Influence of electrolytes on surface texture characteristics generated by electrochemical micromachining

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