Generation of functional surfaces by using a simulation tool for surface prediction and micro structuring of cold-working steel with ultrasonic vibration assisted face milling

Börner, Richard; Winkler, Sebastian; Junge, Thomas; Titsch, Christian; Schubert, Andreas; Drossel, Welf‐Guntram

doi:10.1016/j.jmatprotec.2018.01.027

Cited by 57 publications

(23 citation statements)

References 24 publications

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“…The description of the tool movement along the trajectory was temporally discretized, too. In [14] the approach for the stepwise calculation of the tool position and orientation as a path vector was presented. Considering the requirement for a time efficient simulation, the computational effort is reduced by the simulation of one single rotation, which was afterwards patterned in the distance and the direction of the feed.…”

Section: Methodsmentioning

confidence: 99%

“…¼ of the microstructure, this results in a structural distance of about 18 µm: in one direction, it represents the feed, in the direction of the cutting speed it corresponds to the wavelength . For this reason it was necessary to use tools with a special geometry to prevent a collision between the tool's minor flank face and the generated surface microstructure, which is explained in detail in [14]. With this geometric specifications, the tool have a clearance angle of 40° and therefore, to ensure the stability of the cutting edge, a negative rake angle (-10°).…”

Section: Methodsmentioning

confidence: 99%

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Influence of the surface microstructure on the adhesion of a CVD-diamond coating on steel with a CrN interlayer

2018

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forming tool coating. Most of the forming tools are made of steel, so that especially the coatability of steel by a polycrystalline diamond coating would rise the range of fields of application. The polycrystalline CVD-diamond coatings are deposited by a laser induced plasma CVD process, without a vacuum chamber. Various surface microstructures were investigated regarding their influence on the residual stresses to prevent a flaking of the coating: on the one hand, deterministic structures generated by ultrasonic vibration assisted milling (UVAM) and on the other hand, stochastic structures manufactured by blasting and polishing processes. For the UVAM, a surface prediction tool was used to design the surface microstructure beforehand. All steel substrates (material no. 1.2379) were coated in one batch by high-power impulse magnetron sputtering with a chromium nitride coating with a thickness of 2.4 μm. The specimens were analysed by laser microscopy, scanning electron microscopy, energy-dispersive X-ray spectroscopy and Raman spectroscopy. None of the microstructures investigated in this study was able to prevent delamination of the coating entirely. It could be shown that a roughness higher than Sa 0.1μm supports the interlocking between coating and surface as well as that sharp peaks inhibit a homogenous diamond coating deposition.

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Section: Methodsmentioning

confidence: 99%

Section: Methodsmentioning

confidence: 99%

Influence of the surface microstructure on the adhesion of a CVD-diamond coating on steel with a CrN interlayer

2018

Self Cite

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“…The word dexel consists of the two compound words "depth" and "pixel" according to Niebuhr [26]. Another definition of the word dexel is "depth element" according to van Hook [27] or "discrete points" which are aligned over a regular grid according to Börner et al [28]. Besides the dexel model, Denkena and Tönshoff listed several other discretization models for the workpiece's geometry, such as the voxel model or the polyhedron model [29].…”

Section: Contact Point Radius V Cmentioning

confidence: 99%

“…In most applications with rotating tools, it is sufficient to consider the body of the tool resulting from the rotation (envelope curve) according to Denkena and Tönshoff [29] (see Figure 2b). According to Börner et al, this simplified model is often used for the determination of cutting forces, temperature, or collision calculation [28].…”

Section: Contact Point Radius V Cmentioning

confidence: 99%

Analysis of dimensional accuracy for micro-milled areal material measures with kinematic simulation

Klauer

Eifler

Kirsch

et al. 2021

Int J Adv Manuf Technol

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The calibration of areal surface topography measuring instruments is of high relevance to estimate the measurement uncertainty and to guarantee the traceability of the measurement results. Calibration structures for optical measuring instruments must be sufficiently small to determine the limits of the instruments.Besides other methods, micro-milling is a suitable process for manufacturing areal material measures. For the manufacturing by micro-milling with ball end mills, the tool radius (effective cutter radius) is the corresponding limiting factor: if the tool radius is too large to penetrate the concave profile details without removing the surrounding material, deviations from the target geometry will occur. These deviations can be detected and excluded before experimental manufacturing with the aid of a kinematic simulation.In this study, a kinematic simulation model for the prediction of the dimensional accuracy of micro-milled areal material measures is developed and validated. Subsequently, a radius study is conducted to determine how the tool radius r of the tool influences the dimensional accuracy of an areal crossed sinusoidal (ACS) geometry according to ISO 25178-70 [1] with a defined amplitude d and period length p. The resulting theoretical surface texture parameters are evaluated and compared to the target values. It was shown that the surface texture parameters deviate from the nominal values depending on the effective cutter radius used. Based on the results of the study, it can be determined with which effective tool radius the measurands Sa and Sq of the material measures are best met. The ideal effective radius for the application considered is between 50 and 75 μm.

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“…Tao et al (2017) also analyzed the influence of tool parameters on surface generation, they simplified the tool cutting edge as a sharp one, to simple the simulation process and reduce the computation time, but it reduces the accuracy of the surface texture simulation. Recently, Börner et al (2018) proposed an improved modelling model for textured surface generation in VAMILL. By a dexel-based data model to describe workpiece and tool, actual tool geometry can be considered in the modelling of textured surface generation, this method can improve the simulation accuracy by using small discrete distance, however, its time-consuming.…”

Section: Introductionmentioning

confidence: 99%

Modelling and experimental investigation on textured surface generation in vibration-assisted micro-milling

Chen

Zheng

Xie

et al. 2019

Journal of Materials Processing Technology

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This paper investigates the textured surface generation mechanism in vibration-assisted micro milling through modelling and experimental approaches. To decouple the effects of tool geometry and kinematics of vibration-assisted milling, a surface generation model based on homogenous matrices transformation is proposed. On this basis, series of simulations are performed to provide insights into the effects of various vibration parameters (frequency, amplitude and phase difference) on the generation mechanism of typical textured surfaces in 1D and 2D vibration-assisted milling. Furthermore, the wettability tests are performed on the machined surfaces with various surface texture topographies. The fish-scale textured surfaces are found to exhibit better wettability than those with wavy-structure. The results indicate that vibration-assisted milling is an effective method to generate certain surface textures with controllable wettability.

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Generation of functional surfaces by using a simulation tool for surface prediction and micro structuring of cold-working steel with ultrasonic vibration assisted face milling

Cited by 57 publications

References 24 publications

Influence of the surface microstructure on the adhesion of a CVD-diamond coating on steel with a CrN interlayer

Influence of the surface microstructure on the adhesion of a CVD-diamond coating on steel with a CrN interlayer

Analysis of dimensional accuracy for micro-milled areal material measures with kinematic simulation

Modelling and experimental investigation on textured surface generation in vibration-assisted micro-milling

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