Fast Generation of Planar Micro-Structured Surfaces by Elliptical Vibration Texturing

2016 ◽  
Author(s):  
Yang Yang ◽  
Ping Guo
Keyword(s):  
Simulation Model ◽  
Functional Performance ◽  
Ultrasonic Frequency ◽  
Specific Class ◽  
Structured Surfaces ◽  
High Productivity ◽  
Elliptical Vibration ◽  
Elliptical Vibration Texturing ◽  
Cutting Velocity ◽  
Micro Dimples

Micro-structured surfaces have extensive applications in a wide array of fields, due to their improved functional performance. Existing manufacturing methods for these surfaces fall short of efficiency for volume production or are only applicable to a specific class of materials. In this paper, an innovative and highly-efficient machining method, elliptical vibration texturing (EVT), is proposed for rapid generation of micro-dimples on planar engineered surfaces. The cutting tool of the EVT process vibrates along an elliptical trajectory. The elliptical vibrations, when coupled with a high cutting velocity, impose micro-dimples onto workpiece surfaces while machining. The high productivity is achieved by adopting a newly designed tertiary motion generator which is able to deliver required elliptical vibrations at an ultrasonic frequency. The shape and distribution of the generated dimple patterns have been theoretically analyzed and predicted by a proposed simulation model. Preliminary texturing results using aluminum and brass as workpieces are given to validate the process principle and simulation model.

Fast Generation of Planar Microstructured Surfaces by Elliptical Vibration Texturing

2017 ◽  
Vol 5 (1) ◽  
Author(s):  
Yang Yang ◽  
Ping Guo
Keyword(s):  
Simulation Model ◽  
Functional Performance ◽  
Ultrasonic Frequency ◽  
Specific Class ◽  
High Productivity ◽  
Elliptical Vibration ◽  
Microstructured Surfaces ◽  
Elliptical Vibration Texturing ◽  
Cutting Velocity ◽  
Rapid Generation

Microstructured surfaces have extensive applications in a wide array of fields due to their improved functional performance. Existing manufacturing methods for these surfaces fall short of efficiency for volume production or are only applicable to a specific class of materials. In this paper, an innovative and highly efficient machining method, elliptical vibration texturing (EVT), is proposed for rapid generation of microdimples on planar engineered surfaces. The cutting tool of the EVT process vibrates along an elliptical trajectory. The elliptical vibrations, when coupled with a high cutting velocity, impose microdimples onto workpiece surfaces while machining. The high productivity is achieved by adopting a newly designed tertiary motion generator, which is able to deliver required elliptical vibrations at an ultrasonic frequency. The shape and distribution of the generated dimple patterns have been theoretically analyzed and predicted by a proposed simulation model. Preliminary texturing results using aluminum and brass as workpieces are given to validate the process principle and simulation model.

Fast Generation of Micro-Channels on Cylindrical Surfaces by Elliptical Vibration Texturing

2014 ◽  
Vol 136 (4) ◽  
Author(s):  
Ping Guo ◽  
Yong Lu ◽  
Pucheng Pei ◽  
Kornel F. Ehmann
Keyword(s):  
Process Parameters ◽  
High Efficiency ◽  
Low Cost ◽  
Pattern Generation ◽  
Depth Of Cut ◽  
Channel Formation ◽  
Structured Surfaces ◽  
Elliptical Vibration ◽  
Micro Channels ◽  
Elliptical Vibration Texturing

Micro-structured surfaces are assuming an ever-increasing role since they define the ultimate performance of many industrial components and products. Micro-channels, in particular, have many potential applications in micro-fluidic devices, micro heat exchangers, and friction control. This paper proposes an innovative vibration-assisted machining method to generate micro-channels on the external surface of a cylinder. This method, referred to as elliptical vibration texturing, was originally developed by the authors to generate dimple patterns. It uses the modulation of the depth-of-cut by tool vibrations to create surface textures. The most promising features of the proposed method are its high efficiency, low cost, and scalability for mass production. It is shown that with proper combinations of the process parameters the created dimples start to overlap and form channels. An analytical model is established to predict channel formation with respect to the overlapping ratios of the dimples. Channel formation criteria and expressions for channel geometries are given along with a channel generation map that relates channel geometry to the process parameters. Experimental results are given to verify the model. A further example of micro-pattern generation is also given to showcase the flexibility of the process.

scholarly journals Paradigm shifts in surface metrology. Part II. The current shift

2007 ◽  
Vol 463 (2085) ◽  
pp. 2071-2099 ◽  
Author(s):  
X Jiang ◽  
P.J Scott ◽  
D.J Whitehouse ◽  
L Blunt
Keyword(s):  
Paradigm Shift ◽  
Functional Performance ◽  
Historical Context ◽  
Surface Metrology ◽  
Paradigm Shifts ◽  
Surface Geometry ◽  
Structured Surfaces ◽  
Geometrical Features ◽  
Ultra Precision ◽  
Current Shift

This is the second part of the paper ‘Paradigm shifts in surface metrology’. In part I, the three historical paradigm shifts in surface metrology were brought together, and the subsequent evolution resulting from the shifts discussed. The historical philosophy highlighted the fact that the paradigm shifts must be robust and flexible, meaning that surface metrology must allow for full control of surface manufacture and provide an understanding of the surface functional performance. Part II presents the current paradigm shift as a ‘stepping stone’, building on the above historical context. Aspects of surface geometry will also have to cater for surfaces derived from disruptive application, i.e. structured and freeform surfaces are identified candidates. The current shift is presented in three aspects: from profile to areal characterization; from stochastic to structured surfaces; and from simple geometries to complex freeform geometries, all spanning the millimetre to sub-nanometre scales. In this paradigm shift, the scale of surface texture is beginning to approach some of the geometrical features in micro/nano electro-mechanical systems devices and is becoming one of the most important functionality indicators. Part II will contextualize the current shifts in the discipline of surface metrology, and cement surface metrology in place in the ultra precision and nanotechnology age.

Development of a two-frequency, elliptical-vibration texturing device for surface texturing

2017 ◽  
Vol 31 (7) ◽  
pp. 3465-3473 ◽  
Author(s):  
Rendi Kurniawan ◽  
Tae Jo Ko ◽  
Li Chang Ping ◽  
S. Thirumalai Kumaran ◽  
Gandjar Kiswanto ◽  
...  
Keyword(s):  
Surface Texturing ◽  
Elliptical Vibration ◽  
Elliptical Vibration Texturing

Development of a New Vibrator for Elliptical Vibration Texturing

2011 ◽  
Author(s):  
Ping Guo ◽  
Kornel F. Ehmann
Keyword(s):  
Resonant Mode ◽  
Experimental Result ◽  
Design Parameters ◽  
Vibration Modes ◽  
Turning Process ◽  
Vibration Cutting ◽  
Elliptical Vibration ◽  
Preliminary Experimental Result ◽  
Elliptical Vibration Texturing ◽  
Cutting Direction

Inspired by the idea of vibro-mechanical texturing, which adds a tertiary motion to the tool tip in the conventional turning process, and the elliptical vibration cutting process, which adds vibrations both in the cutting direction and feed direction, this paper proposes a new design for an ultrasonic vibrator for the elliptical vibration texturing process. The elliptical locus lies in the plane that is defined by the cutting and the radial directions. The device could be easily adapted for elliptical cutting applications by changing the orientation of the tool tip. The vibrator works in the resonant mode, with in-phase and anti-phase vibration modes at a nearly identical natural frequency. Simulations and experiments have been carried out to study and verify different vibration modes of the system. Different design parameters have been analyzed to control the elliptical trajectory of the tool tip. A set of preliminary experimental result of elliptical vibration texturing is also provided.

Modeling the Force, Surface Roughness and Cutting Temperature in Ultrasonic Vibration-Assisted Turning of Al7075

2009 ◽  
Vol 83-86 ◽  
pp. 315-325 ◽  
Author(s):  
Mohammad Javad Nategh ◽  
Saeed Amini ◽  
H. Soleimanimehr
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
Single Point ◽  
Cutting Temperature ◽  
Depth Of Cut ◽  
Ultrasonic Frequency ◽  
Factorial Experiments ◽  
Machining Force ◽  
Cutting Velocity ◽  
Full Factorial

The single point cutting tool in ultrasonic vibration-assisted turning (UAT) is made to vibrate under ultrasonic frequency. In present study, the influence of various parameters such as vibration amplitude, depth of cut, feed rate and cutting velocity on the machining force and workpiece's surface roughness in UAT of Al7075 has been investigated. Full factorial experiments were carried out with an ultrasonic frequency range of 20±0.5 kHz. ANOVA was conducted on the experimental results and regression models were obtained for predicting the machining force, surface roughness and cutting temperature. The proposed models were verified by further experiments. The robustness of the proposed models was then investigated whence the optimal parameters were estimated. Similar full factorial experiments were also carried out with conventional turning (CT) in order to compare the results with those of UAT.

Experimental Study of Microgroove Surface Using Three-Dimensional Elliptical Vibration Texturing

2019 ◽  
Vol 7 (2) ◽  
Author(s):  
Rendi Kurniawan ◽  
Saood Ali ◽  
Ki Moon Park ◽  
Sang Tae Jung ◽  
Tae Jo Ko
Keyword(s):  
Experimental Study ◽  
Three Dimensional ◽  
Cutting Speed ◽  
Machined Surface ◽  
Elliptical Vibration ◽  
Microstructured Surface ◽  
Microstructured Surfaces ◽  
Elliptical Vibration Texturing ◽  
Preliminary Study ◽  
Cutting Speeds

This paper presents our preliminary study of the microstructured surface on microgrooves patterns, which have manufactured using the three-dimensional elliptical vibration texturing (3D-EVT) method. The 3D-EVT method uses a three-dimensional trajectory of elliptical locus of the cutting tool tip in high vibration frequency to fabricate the microstructure or the vibration mark pattern on the machined surface. The experimental study has been done with a variation of the nominal cutting speeds from 300 to 600 mm/min. The preliminary results showed that in the low nominal cutting speed of 300 and 450 mm/min, the microstructured surfaces were not manufactured well due to the bulging existence on the microstructured surface in which it is correlated with the build-up edge phenomena. On the other hand, a relative excellent microstructured surface can be achieved at the higher nominal cutting speed of 600 mm/min. In addition, a lubricant could be used to obtain an excellent microstructured surface to avoid the built-up edge phenomena.

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