Microstructuring of Surfaces by Two-stage Vibration-assisted Turning

Zhang, R.; Steinert, Philipp; Schubert, Andreas

doi:10.1016/j.procir.2014.03.026

Cited by 18 publications

(6 citation statements)

References 7 publications

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“…It is widely known that LST, owing to its flexibility and high precision ability, is a favorable choice for dimple fabrication to improve tribological performance. However, due to the high manufacturing cost and energy consumption, other texturing techniques, such as machining process, are becoming more prevalent (Zhang et al, 2014). Recently, dynamic assisted tooling (DATT) has been developed to fabricate dimple via turning process, with the advantage of lower manufacturing cost and greener working environment (Dali et al, 2017).…”

Section: Introductionmentioning

confidence: 99%

Computational fluid dynamic study on the tribological performance of dimple-textured surface fabricated using the turning process

Rahman

Ghani

Mahmood

et al. 2019

ILT

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Purpose This study aims to simulate the influence of surface texturing produced via turning process toward pressure distribution and load capacity generation using computational fluid dynamics (CFD). Design/methodology/approach The dimple geometry was obtained via turning process, to be used for future application on piston skirt surfaces. Two cases were studied: a preliminary study using single periodic dimple assuming linear dimple distribution and an application study using multiple periodic dimples to address actual dimple orientation following the turning process. Findings For the first case, the dimple was proven to generate load capacity with regard to untextured surface, owing to the asymmetric pressure distribution. Increasing the Reynolds number, dimple width and dimple depth was found to increase load capacity. For the second case, although load capacity increases via surface texturing, the value was 97.4 per cent lower relative to the first case. This confirmed the importance of doing multiple dimple simulations for real applications to achieve more realistic and accurate results. Originality/value A new concept of dimple fabrication using a low-cost turning process has been developed, with a potential to increase the tribological performance under hydrodynamic lubrication. Previous CFD simulations to simulate these benefits have been done using a single periodic dimple, assuming equal distribution array between dimples. However, due to the different orientations present for dimples produced using turning process, a single periodic dimple simulation may not be accurate, and instead, multiple dimple simulation is required. Therefore, present research was conducted to compare the results between these two cases and to ensure the accuracy of CFD simulation for this type of dimple.

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Section: Introductionmentioning

confidence: 99%

Computational fluid dynamic study on the tribological performance of dimple-textured surface fabricated using the turning process

Rahman

Ghani

Mahmood

et al. 2019

ILT

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“…Machining process is found to be the best method to fabricate dimple structure (Roy et al , 2014; Matsumura et al , 2014). This finding is supported by Zhang et al (2014), in which machining process has the absolute advantage in terms of low cost, lower energy required and shorter fabrication time.…”

Section: Introductionmentioning

confidence: 67%

“…Machining parameters that are effective in dimple structure fabrication in terms of shapes and patterns depend on three main parameter, i.e. cutting parameter [cutting speed, feed rate, depth of cut (DOC)], vibration (frequency, amplitude) and cutting tool geometry (Guo and Ehmann, 2013; Suzuki et al , 2011; Zhang et al , 2014). With the use of frequencies of 28, 36.15 and 24, all the three researchers had managed to produce various shape and patterns of dimple structure.…”

Section: Introductionmentioning

confidence: 99%

Fabrication of dimple structured surface of A390 Al-Si alloy using turning process

Dali

Ghani

Haron

et al. 2017

ILT

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Purpose The purpose of this paper is to produce dimple structure on a cylindrical surface for Aluminium-Silicon (Al-Si) alloy piston (A390) using turning process. The process selection is based on factors such as the capability of machining process, low cost process, minimum set up time and green working environment. Design/methodology/approach Three main machining parameters that greatly influenced the dimple structure fabrication were identified from previous researches (cutting parameters, vibration and cutting tool geometry). To facilitate dimple structure fabrication using turning process, a dynamic assisted tooling (DATT) was developed. Experiments were conducted on Al-Si A390 material for future application of automotive piston. A three-dimensional surface profiler (Alicona) was used for geometry measurement and analysis of dimple structure. The Taguchi method, with an L8 orthogonal array, was used to accommodate seven parameters used in the fabrication of dimpled structures using turning process. Signal-to-noise (S/N) ratio and observation on the shape of dimple structure array were used to determine the optimum machining condition. Findings Optimum parameters obtained using S/N ratio analysis were cutting speed of 9 m/min, depth of cut of 0.01 mm, amplitude displacement of 1 mm, nose radius of 0.4 mm and frequency of (25 Hertz). Whereas feed rate, rake and relief angles were not significant to the size, shape and dimple array; therefore, their selected values depend on requirement of the application. Based on the S/N ratio and uniformity of the array of dimple structure as the main reference, the sixth and eighth experiment conditions almost achieved the optimum condition which are able to produce the width of dimple structure of 396.82 and 560.43 μm, respectively, dimple length of 3,261.6 and 2,422.7 μm, respectively, dimple depth of 63.43 and 65.97 μm, respectively, area ratio of 10 and 10.39 per cent, respectively, and surface roughness of 3.0023 and 3.0054 μm, respectively. These results are within the range of dimple structure obtained by the previous researchers for sliding mechanical components application. Originality/value The optimum condition of machining parameters in producing uniform dimple structure led to the compilation of data base in dimple structure research via turning process. Dimple structure produced is similarly obtained with other processes like laser, burnishing, photochemical, etc. DATT developed has the ability to produce repeatable vibration frequency, stable and consistent amplitude displacement using a simple crank concept and structure that can be mounted on all types of lathe machine either conventional or computer numerical control.

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“…Manufacturing microstructures in one process step is a highly productive process. Zhang et al [8] proposed a two-stage process, where dimples are generated on a surface. First, a microstructured surface is machined by using ultrasonic vibration-assisted turning.…”

Section: Introductionmentioning

confidence: 99%

Feasibility Study for Monitoring an Ultrasonic System Using Structurally Integrated Piezoceramics

Werner,

Krüger,

Drossel

2024

Sensors

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This paper presents a new approach to monitoring ultrasonic systems using structurally integrated piezoceramics. These are integrated into the sonotrode at different points and with different orientations. The procedure for integrating the piezoceramics into the sonotrode and their performance is experimentally investigated. We examine whether the measured signal can be used to determine the optimal operating frequency of the ultrasonic system, if integrating several piezoceramics enables discernment of the current vibration shape, and if the piezoceramics can withstand the high strains caused by the vibrations in a frequency range of approximately 20–25 kHz. The signals from the piezoceramic sensors are compared to the real-time displacement at different points of the sonotrode using a 3D laser scanning vibrometer. To evaluate the performance of the sensors, different kinds of excitation of the ultrasonic system are chosen.

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Microstructuring of Surfaces by Two-stage Vibration-assisted Turning

Cited by 18 publications

References 7 publications

Computational fluid dynamic study on the tribological performance of dimple-textured surface fabricated using the turning process

Computational fluid dynamic study on the tribological performance of dimple-textured surface fabricated using the turning process

Fabrication of dimple structured surface of A390 Al-Si alloy using turning process

Feasibility Study for Monitoring an Ultrasonic System Using Structurally Integrated Piezoceramics

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