Surfaces by vibration/modulation-assisted texturing for tribological applications

Gandhi, Rahul; Sebastian, Diaz De La Torre; Basu, Saurabh; Mann, James B.; Iglesias, Patricia; Saldaña, Christopher

doi:10.1007/s00170-015-7968-3

Cited by 23 publications

(12 citation statements)

References 27 publications

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“…Through these studies, it was shown that nanocrystalline, nanotwinned and ultra fine grain (UFG) microstructures exhibit better corrosion response [3], fatigue resistance [4] and thermal stability [5], respectively. Complimentary to these studies, single variable functional response of topographically feature rich surfaces have showed direct correlation between surface topography and performance measures such as bio-compatibility [6] and wear [7].…”

Section: Introductionmentioning

confidence: 99%

“…While these techniques provide capability for high spatial resolution and precision, scalable implementation for controlled surface design is severely hampered by the high cost of capital equipment. In comparison, shear-based surface generation using transient material removal processes offers a scalable alternative for integrating sophisticated microstructural and topographical designs into fabricated components [7,11]. This process involves advancing a wedge shaped tool across a work surface in a periodic manner so to control the engagement and disengagement of the tool from the work surface.…”

Section: Introductionmentioning

confidence: 99%

“…This process involves advancing a wedge shaped tool across a work surface in a periodic manner so to control the engagement and disengagement of the tool from the work surface. The resulting effect is a continuously varying surface topography which can be harnessed to yield a range of surface designs, including micro-scale ribs, fins and dimples [7,11]. While considerations pertaining to surface topography control have been well addressed, the integrated surface mechanics and microstructure consequences are not as well understood.…”

Section: Introductionmentioning

confidence: 99%

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Enhanced subsurface grain refinement during transient shear-based surface generation

et al. 2016

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a b s t r a c tThe present work combines quantitative orientation imaging microscopy and in situ digital image correlation to identify heterogeneities in the coupled mechanics and microstructure evolution occurring in the deformed subsurface during transient shear-based surface generation. Subsurface microstructure exhibited heterogeneities in terms of thickness of the ultrafine-grained layer and recrystallization fraction as a function of position along the surface wavelength. It was observed that subsurface microstructure evolution followed accelerated recrystallization kinetics due to strain path changes occurring in the subsurface during transient surface generation. The magnitudes of these strain path changes and prestraining of the deformed subsurface were observed to correlate well with changes in the information entropy of the corresponding subsurface crystallographic textures. A phenomenological model for predicting the information entropy of the orientation distribution function based on strain path changes and strain history was formulated and validated for monotonic loading paths. The implications of this generalized framework for modeling and controlling subsurface microstructure in transient surface generation are briefly discussed.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Enhanced subsurface grain refinement during transient shear-based surface generation

et al. 2016

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“…Shamoto and Moriwaki [14] first developed the elliptical vibration-assisted cutting (EVC) technique that can be used to mitigate the problem of diamond tool's chemical wear while machining ferrous metals [15,16]. Meanwhile, this technique has also been applied by many researchers to manufacture microstructures [17][18][19], nanostructures [20] and hybrid micro/nanostructures [21]. Compared with conventional diamond cutting, the intermittent tool/workpiece contact endows the elliptical vibration-assisted diamond cutting technique with not only a surface-texturing ability but also chipbreaking [22] and burr-suppression [23] features.…”

Section: Introductionmentioning

confidence: 99%

A high-frequency non-resonant elliptical vibration-assisted cutting device for diamond turning microstructured surfaces

Wang

Luo

Liu

et al. 2021

Int J Adv Manuf Technol

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In recent years, research has begun to focus on the development of non-resonant elliptical vibration-assisted cutting (EVC) devices, because this technique offers good flexibility in manufacturing a wide range of periodic microstructures with different wavelengths and heights. However, existing non-resonant EVC devices for diamond turning can only operate at relatively low frequencies, which limits their machining efficiencies and attainable microstructures. This paper concerns the design and performance analysis of a non-resonant EVC device to overcome the challenge of low operational frequency. The structural design of the non-resonant EVC device was proposed, adopting the leaf spring flexure hinge (LSFH) and notch hinge prismatic joint (NHPJ) to mitigate the cross-axis coupling of the reciprocating displacements of the diamond tool and to combine them into an elliptical trajectory. Finite element analysis (FEA) using the mapped meshing method was performed to assist the determination of the key dimensional parameters of the flexure hinges in achieving high operational frequency while considering the cross-axis coupling and modal characteristics. The impact of the thickness of the LSFH on the sequence of the vibrational mode shape for the non-resonant EVC device was also quantitatively revealed in this study. Moreover, a reduction in the thickness of the LSFH can reduce the natural frequency of the non-resonant EVC device, thereby influencing the upper limit of its operational frequency. It was also found that a decrease in the neck thickness of the NHPJ can reduce the coupling ratio. Experimental tests were conducted to systematically evaluate the heat generation, cross-axis coupling, modal characteristics and diamond tool’s elliptical trajectory of a prototype of the designed device. The test results showed that it could operate at a high frequency of up to 5 kHz. The cross-axis coupling ratio and heat generation of the prototype are both at an acceptable level. The machining flexibility and accuracy of the device in generating microstructures of different wavelengths and heights through tuning operational frequency and input voltage have also been demonstrated via manufacturing the micro-dimple arrays and two-tier microstructured surfaces. High-precision microstructures were obtained with 1.26% and 10.67% machining errors in wavelength and height, respectively.

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“…Vibration assisted texturing (VAT) is a more recent variant of VAM aiming to fabricate textured or structured surfaces by superimposing vibrations at the machining finishing process. Compared to alternative texturing approaches, the advantages are the application for large surface area finishing and cost reduction [5,6]. Furthermore, microstructured surfaces could be beneficial from a tribological point of view [6,7].…”

Section: Introductionmentioning

confidence: 99%

Design of Contactlessly Powered and Piezoelectrically Actuated Tools for Non-Resonant Vibration Assisted Milling

Silge

Sattel

2018

Actuators

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This contribution presents a novel design approach for vibration assisted machining (VAM). A lot of research has already been done regarding the influence of superimposed vibrations during a milling process, but there is almost no information about how to design a VAM tool where the tool is actually rotating. The proposed system consists of a piezoelectric actuator for vibration excitation, an inductive contactless energy transfer system and an electronic circuit for powering the actuated tool. The main benefit of transferring the required power without mechanical contact is that the maximum spindle speed is no longer restricted by friction of slip rings. A detailed model is shown that enables for preliminary estimation of the system's response to different excitation signals. Experimental data are provided to validate the model. Finally, some parts are shown that have been manufactured using the contactlessly actuated milling tool.Actuators 2018, 7, 19 2 of 17 apparent power operation. The vibration frequency and necessary stroke determine the type of the piezoelectric actuator.In VAM, when enhancing the machining process enhancement, e.g., cutting force and tool wear reduction or chip breakage improvement, is the focus, the piezoelectric actuators are driven at a single excitation frequency in resonance operation mode. The used frequencies are mainly in the ultrasonic frequency range. The advantage of high vibration frequencies is a higher possible upfeed velocity and thus decreased machining time at a given rate of vibrations per tool revolution [1] (p. 157).Research in VAT is based on non-resonant piezoelectric actuation to allow for nearly arbitrary periodic vibration forms of the tool tip. Both one-and two dimensional vibrations of either the tool tip or the workpiece are under investigation. Almost all actuators designed for examining VAT are non-rotating devices [8][9][10][11]. In [10], a 1D-actuator design was suggested and investigated that allows for vibration frequencies from DC up to 40 kHz. This enlarged frequency range comes at the cost of larger actuator volume. An off-the-shelf 1D-actuator for examining texturing under turning processes was chosen in [8]. As an add-on tool for conventional machines, Ref.[11] developed a 2D-actuator for elliptic cutting processes with rotating workpieces. Similarly, Ref.[12] developed and investigated an 2D-actuator for elliptic VAT in milling processes. There, the actuator is embedded in a cooling chamber. Contrary to the others, in [9], it is not the tool that is actuated but the workpiece, which limits their sizes. The application is also a milling process.Up to now, only Ref.[13] suggests a milling tool with an integrated rotating piezoelectric actuator. This tool allows for arbitrary cutting profiles. Using a specially shaped cutting plate, they showed the possibility to cut nearly any pattern into the surface of an object. The main disadvantage of this system is that the electrical power is transferred to the actuator using slip rings; therefore, the cutting...

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Surfaces by vibration/modulation-assisted texturing for tribological applications

Cited by 23 publications

References 27 publications

Enhanced subsurface grain refinement during transient shear-based surface generation

Enhanced subsurface grain refinement during transient shear-based surface generation

A high-frequency non-resonant elliptical vibration-assisted cutting device for diamond turning microstructured surfaces

Design of Contactlessly Powered and Piezoelectrically Actuated Tools for Non-Resonant Vibration Assisted Milling

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