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Research Papers

Fast Generation of Planar Microstructured Surfaces by Elliptical Vibration Texturing

[+] Author and Article Information
Yang Yang

Department of Mechanical and Automation Engineering,
The Chinese University of Hong Kong,
Hong Kong, China

Ping Guo

Mem. ASME
Department of Mechanical and Automation Engineering,
The Chinese University of Hong Kong,
Hong Kong, China
e-mail: pguo@mae.cuhk.edu.hk

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MICRO- AND NANO-MANUFACTURING. Manuscript received September 16, 2016; final manuscript received November 25, 2016; published online January 6, 2017. Editor: Jian Cao.

J. Micro Nano-Manuf 5(1), 011004 (Jan 06, 2017) (7 pages) Paper No: JMNM-16-1048; doi: 10.1115/1.4035390 History: Received September 16, 2016; Revised November 25, 2016

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.

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Figures

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Fig. 1

Schematics of (a) the EVC process and (b) the EVT process

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Fig. 2

Schematic diagram of the EVT process

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Fig. 3

Geometry diagram of generated dimple arrays

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Fig. 4

Description of the cutting tool geometry

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Fig. 5

Tertiary motion generator and tuning experiment setup: 1—base block; 2—end masses; 3—piezoelectric rings; 4—head flexure; 5—cutting insert; and 6—capacitance displacement sensors

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Fig. 6

Measured tool vibration trajectory: (a) displacement data and (b) two-dimensional trajectory

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Fig. 7

Experimental setup: (1) X–Y–Z motion stage; (2) linear motor actuator; (3) acrylic adaptor; (4) workpiece; and (5) tertiary motion generator (TMG)

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Fig. 8

Surface profile of premachined surfaces

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Fig. 9

Textured surface profiles: (a) aluminum alloy 6061 and (b) brass C3600

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Fig. 10

Simulated surface profiles: (a) aluminum alloy 6061 and (b) brass C3600

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Fig. 11

Surface profiles in the cutting direction: (a) v = 1000 mm/s, ADOC = 0 and (b) v = 1500 mm/s, ADOC = 0

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Fig. 12

Simulation results of surface profiles in the cutting direction: (a) v = 1000 mm/s, ADOC = 0 and (b) v = 1500 mm/s, ADOC = 0

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Fig. 13

Surface profiles alone the cutting direction with v = 1000 mm/s and (a) ADOC = −1 μm and (b) ADOC = 1 μm

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Fig. 14

Scanning electron microscope (SEM) micrograph of textured surface with v = 1500 mm/s, ADOC = −1 and cross feed = 50 μm

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