Manufacturing of multiscale structured surfaces

Brinksmeier, E.; Karpuschewski, Bernhard; Yan, Jiwang; Schönemann, Lars

doi:10.1016/j.cirp.2020.06.001

Cited by 84 publications

(35 citation statements)

References 194 publications

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“…Regardless of whether the preload was 20, 10, or 5 mN, with the change of the widths of the biomimetic structures from 100 to 10 μm, the friction force exhibited the same increasing trend, which corresponds to the two parts of the binomial theorem of tribology where A is the real contact area, W is the normal force, and α and β are the friction coefficients determined by the physical and mechanical properties of the friction surface, respectively. 34 According to the binomial theorem of tribology, friction is composed of the mechanical force caused by overcoming mechanical engagement and the molecular force caused by resisting molecular attraction. When the width decreased from 100 to 20 μm, the mechanical force and the molecular force were in competition during the entire process.…”

Section: Resultsmentioning

confidence: 99%

“…Although aluminum is the most commonly used mold material, it is susceptible to thermal deformation during ultraprecision cutting, which affects the machining accuracy. 43 In the present study, tungsten carbide with a Ni–P plating with a thickness of 600 μm was used as the mold material. Compared with tungsten carbide materials, the Ni–P plating can not only reduce the hardness of the mold materials, which can reduce tool wear and improve the service life of the materials, but also enhance the quality of the machined surface due to its superior uniformity, smoothness, and compactness.…”

Section: Methodsmentioning

confidence: 99%

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Gecko-Inspired Biomimetic Surfaces with Annular Wedge Structures Fabricated by Ultraprecision Machining and Replica Molding

et al. 2021

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The current research on gecko-inspired dry adhesives is focused on micropillar arrays with different terminal shapes, such as flat, spherical, mushroom, and spatula tips. The corresponding processing methods are mostly chemical methods, including lithography, etching, and deposition, which not only are complex, expensive, and environmentally unfriendly, but also cannot completely ensure microstructural integrity or performance stability. The present study demonstrates a high-precision, high-efficiency, and green method for the fabrication of a gecko-inspired surface, which can promote its application in dexterous robot hands and mechanical grippers. Based on the bendable lamellar structures of the gecko, annular wedge adhesive surfaces that stick to the finger surfaces of dexterous robot hands to improve their load capacity are proposed and fabricated via a suitable combined processing method of ultraprecision machining and replica molding. The greater the width, the higher the replication integrity, and when the minimum width is 20 μm, the replication error is less than 5.5% due to the superior processing performance of the nickel–phosphorus (Ni–P) plating of the master mold. The fabricated annular wedge structures with an optimized width of 20 μm not only exhibit a strong friction force of up to 35.48 mN under a preload of 20 mN in the GCr15/poly(dimethylsiloxane) (PDMS) friction pair but also demonstrate an obviously improved anisotropic friction characteristic of up to λ = 1.36, as the molecular force exhibits a stronger increase as compared to the decrease of the mechanical force of the structure with a small width.

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Section: Resultsmentioning

confidence: 99%

Section: Methodsmentioning

confidence: 99%

Gecko-Inspired Biomimetic Surfaces with Annular Wedge Structures Fabricated by Ultraprecision Machining and Replica Molding

et al. 2021

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“…The fabrication of micro-structured surfaces can be realized by a variety of nonmechanical methods, such as beam based processing, electrical machining, lithography, and chemically assisted manufacturing [8]. As one of the mechanical methods, ultraprecision diamond cutting is popularly used for micro-structure machining, because it can directly create complex micro-structured surface with high accuracy and surface quality [9,10].…”

Section: Introductionmentioning

confidence: 99%

Fundamental Investigation of Diamond Cutting of Micro V-Shaped Grooves on a Polycrystalline Soft-Brittle Material

Huang¹,

Yan²

2021

JMMP

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Fabricating micro-structures on optical materials has received great interest in recent years. In this work, micro-grooving experiments were performed on polycrystalline zinc selenide (ZnSe) to investigate the feasibility of surface micro-structuring on polycrystalline soft-brittle material by diamond turning. A photosensitive resin was coated on the workpiece before cutting, and it was found that the coating was effective in suppressing brittle fractures at the edges of the grooves. The effect of tool feed rate in groove depth direction was examined. Results showed that the defect morphology on the groove surface was affected by the tool feed rate. The crystallographic orientation of grains around the groove was characterized by electron backscatter diffraction (EBSD), and it was found that the formation of defects was strongly dependent on the angle of groove surface with respect to the cleavage plane of grain. The stress distribution of the micro-grooving process was investigated by the finite element method. Results showed that the location of tensile stresses in the coated workpiece was farther from the edge of the groove compared with that in the uncoated workpiece, verifying the experimental result that brittle fractures were suppressed by the resin coating.

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“…In many cases, these surfaces are inspired by examples found in nature, such as the lotus leaf, the skin of sharks, or the hierarchical adhesive apparatus found on the feet of geckos and certain arthropods. Reviews can be found in [ 2 , 3 , 4 , 5 ]. In most cases, the fabrication of these surfaces begins with lithographic patterning or direct micromachining of a material such as SU-8 [ 6 ], wax [ 7 ], or silicon to create a mold, which is used to cast the functional material.…”

Section: Introductionmentioning

confidence: 99%

FEM and Analytical Modeling of the Incipient Chip Formation for the Generation of Micro-Features

et al. 2021

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This paper explores the modeling of incipient cutting by Abaqus, LS-Dyna, and Ansys Finite Element Methods (FEMs), by comparing also experimentally the results on different material classes, including common aluminum and steel alloys and an acetal polymer. The target application is the sustainable manufacturing of gecko adhesives by micromachining a durable mold for injection molding. The challenges posed by the mold shape include undercuts and sharp tips, which can be machined by a special diamond blade, which enters the material, forms a chip, and exits. An analytical model to predict the shape of the incipient chip and of the formed grove as a function of the material properties and of the cutting parameters is provided. The main scientific merit of the current work is to approach theoretically, numerically, and experimentally the very early phase of the cutting tool penetration for new sustainable machining and micro-machining processes.

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Manufacturing of multiscale structured surfaces

Cited by 84 publications

References 194 publications

Gecko-Inspired Biomimetic Surfaces with Annular Wedge Structures Fabricated by Ultraprecision Machining and Replica Molding

Gecko-Inspired Biomimetic Surfaces with Annular Wedge Structures Fabricated by Ultraprecision Machining and Replica Molding

Fundamental Investigation of Diamond Cutting of Micro V-Shaped Grooves on a Polycrystalline Soft-Brittle Material

FEM and Analytical Modeling of the Incipient Chip Formation for the Generation of Micro-Features

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