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Research Papers

Efficient Machining of Microdimples for Friction Reduction

[+] Author and Article Information
B. Denkena

e-mail: denkena@ifw.uni-hannover.de

J. Köhler

e-mail: koehler@ifw.uni-hannover.de

J. Kästner

e-mail: kaestner@ifw.uni-hannover.de

T. Göttsching

e-mail: goettsching@ifw.uni-hannover.de
Institute of Production Engineering
and Machine Tools (IFW),
Leibniz Universität Hannover, Germany

F. Dinkelacker

e-mail: dinkelacker@itv.uni-hannover.de

H. Ulmer

e-mail: ulmer@itv.uni-hannover.de
Institute of Technical Combustion (ITV),
Leibniz Universität Hannover, Germany

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MICRO AND NANO-MANUFACTURING. Manuscript received October 4, 2012; final manuscript received January 22, 2013; published online March 25, 2013. Assoc. Editor: Stefan Dimov.

J. Micro Nano-Manuf 1(1), 011003-011008-8 (Mar 25, 2013) (8 pages) Paper No: JMNM-12-1065; doi: 10.1115/1.4023757 History: Received October 04, 2012; Revised January 22, 2013

In order to improve the tribological properties of thermomechanically highly stressed surfaces such as cylinder liners, microdimples are produced by fly-cutting kinematics along the functional surface. The structures are used to hold back lubricant but also to increase the hydrodynamic pressure, which is built up between the sliding friction partners. For that, machining strategies for the pattern generation in cylindrical components are developed as well as a mathematical model of the microdimple arrangement and distribution. The tribological performance of the machined microdimples is analyzed by means of ring-on-disk experiments. At low sliding speeds the friction coefficient can be decreased clearly by microdimples. This indicates the potential for low-speed or reciprocating tribosystems like cylinder liners. This potential is quantified by motor driven experiments and the comparison between structured and nonstructured cylinder liners. A honed (fine) liner with additional microdimples along the interstice area shows friction losses up to 19% compared to standard honed nonstructured cylinder liner.

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Figures

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Fig. 1

Principle of hydrodynamic pressure build up by geometrically defined microdimples

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Fig. 2

Axially parallel and orthogonal machining strategies for cylindrical components

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Fig. 3

Characterizing parameters for the dimple distribution and arrangement

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Fig. 4

Interrelationship between the revolution ratio and the resulting microdimple arrangement

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Fig. 5

Impact of the milling strategy and the revolution ratio on the stretching and compression ratio

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Fig. 6

Process limits in down milling

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Fig. 7

Ring-on-disk tribometer setup evaluate the tribological performance of machined microdimples

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Fig. 8

Tribological performance of microdimpled surfaces

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Fig. 9

Impact of the microdimple density, the depth and the flank angle on the friction coefficient

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Fig. 10

Experimental preparation of cylinder liners

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Fig. 11

Development of the friction mean effective pressure (FMEP)

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