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Surface topography analysis in three-dimensional elliptical vibration texturing (3D-EVT)

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Abstract

In this paper, we investigated the microstructured patterns generated on a machined surface during the fabrication of microgrooves using a three-dimensional elliptical vibration (3D-EVT) method. The microstructures in the form of vibration marks were produced as an effect of the overlapping of the elliptical motion of the tool tip in three dimensions. A three-dimensional ultrasonic elliptical device (3D-UED) was developed in a previous study to vibrate a 3D elliptical locus at an ultrasonic frequency of approximately 20.4 kHz. In this study, the microstructured patterns were fabricated with a nominal depth of cut of 10 μm using an ultrasonic frequency (fm) of 20.4 kHz and by varying the nominal cutting speed from 600 to 1500 mm/min. The experimental results reveal that the pitch increases with the nominal cutting speed. The effect of the cutting tool edge on the microstructured pattern was also investigated by comparing the machined surfaces fabricated using single crystal diamond (SCD) and polycrystalline diamond (PCD). The microstructured pattern using a SCD tool has a better quality compared with a PCD tool. Furthermore, the elastic recovery theory is introduced to explain the surface roughness observed through simulation. The elastic recovery value has been found to increase as the nominal cutting speed increases. In addition, the 3D-EVT method reduces the surface roughness and the cutting forces during texturing.

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Funding

This research was supported by the Basic Science Research through the National Research Foundation of Korea (NRF) funded by the Ministry of Science, ICT, and Future Planning (grant number NRF-2017R1A2B2003932). In addition, this work was partially supported by the Basic Science Research Program through the National Research Foundation of Korea (NRF) funded by the Ministry of Education (NRF-2017R1A4A1015581).

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Authors and Affiliations

  1. School of Mechanical Engineering, Yeungnam University, 214-1 Dae-dong, Gyeongsan-si, Gyeongsangbuk-do, 712-749, South Korea

    Rendi Kurniawan & Tae Jo Ko

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  1. Rendi Kurniawan
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  2. Tae Jo Ko
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Correspondence to Tae Jo Ko.

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Kurniawan, R., Ko, T.J. Surface topography analysis in three-dimensional elliptical vibration texturing (3D-EVT). Int J Adv Manuf Technol 102, 1601–1621 (2019). https://doi.org/10.1007/s00170-018-03253-1

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  • DOI: https://doi.org/10.1007/s00170-018-03253-1

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