Skip to main content
SpringerLink
Log in

Process analysis and hole type optimization of micro-groove multi-pass rolling

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

The micro-grooves with special structure and size have the special function of reducing surface flow resistance. Placing the micro-grooves over a larger area on the aircraft surface can achieve effective drag reduction, that is, a decrease in the resistance experienced during operation. Rolling method can be used to form micro-grooves on metal surface efficiently. However, the micro-grooves formed by this plastic forming method may have some defects, which in turn could cause serious negative impact on the drag reduction and mechanical properties of the micro-grooves. Therefore, optimization of the multi-pass rolling process to avoid the micro-groove defects is of great significance. This paper includes a series of analysis on the microstructure, strain, and material displacement of micro-grooves, which were carried out to explain the causes of micro-groove defects. Micro-grooves were formed on the surface of the sheet, and the plate also underwent both thickness reduction and extension in the Y-direction, under the pressure exerted by the roller. It was found that the extension of the plate had an adverse effect on the formation of micro-grooves; thus, the hole types of the roller were optimized accordingly. The simulation and experimental results showed that the optimized roller could produce the desired micro-grooves, which perfectly eliminated the generation of micro defects.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16

Similar content being viewed by others

Availability of data and materials

All data generated or analyzed during this study are included in this article.

References

  1. Kurita M, Nishizawa A, Kwak D, Iijima H, Iijima Y, Takahashi H et al (2018) Flight test of a paint-riblet for reducing skin-friction. Journal. https://doi.org/10.2514/6.2018-3005

    Article  Google Scholar 

  2. Takahashi H, Kurita M, Koga S, Endo S (2018) Evaluation of skin friction drag reduction in turbulent boundary layer using riblets. Journal. https://doi.org/10.2514/6.2018-0839

    Article  Google Scholar 

  3. Szodruch J (1991) Viscous drag reduction on transport aircraft. 29th Aerospace Sciences Meeting. Am Inst Aeronaut Astronaut

  4. Martin S, Bhushan B (2016) Modeling and optimization of shark-inspired riblet geometries for low drag applications. J Colloid Interface Sci 474:206–15. https://doi.org/10.1016/j.jcis.2016.04.019

  5. Bechert DW, Bruse M, Hage W (2000) Experiments with three-dimensional riblets as an idealized model of shark skin. Exp Fluids 28:403–412

    Article  Google Scholar 

  6. Bechert DW, Hage W (2006) Drag reduction with riblets in nature and engineering. WIT Transactions on State of the Art in Science and Engineering 2:457–504. https://doi.org/10.2495/1-84564-095-0/5g

    Article  Google Scholar 

  7. Daniello RJ, Waterhouse NE, Rothstein JP (2009) Drag reduction in turbulent flows over superhydrophobic surfaces. Phys Fluids 21:085103. https://doi.org/10.1063/1.3207885

    Article  MATH  Google Scholar 

  8. Bechert DW, Bruse M, Hage W, Meyer R (2000) Fluid mechanics of biological surfaces and their technological application. Naturwissenschaften 87:157–171. https://doi.org/10.1007/s001140050696

    Article  Google Scholar 

  9. Bixler GD, Bhushan B (2013) Shark skin inspired low-drag microstructured surfaces in closed channel flow. J Colloid Interface Sci 393:384–96. https://doi.org/10.1016/j.jcis.2012.10.061

  10. Bhushan B (2016) Shark-skin surface for fluid-drag reduction in turbulent flow. In: Bhushan B (ed) Biomimetics: Bioinspired Hierarchical-Structured Surfaces for Green Science and Technology. Springer International Publishing, Cham, pp 327–382

    Chapter  Google Scholar 

  11. Denkena B, Kästner J, Wang B (2010) Advanced microstructures and its production through cutting and grinding. CIRP Ann 59:67–72. https://doi.org/10.1016/j.cirp.2010.03.066

    Article  Google Scholar 

  12. Bixler GD, Bhushan B (2013) Fluid drag reduction with shark-skin riblet inspired microstructured surfaces. Adv Func Mater 23:4507–4528. https://doi.org/10.1002/adfm.201203683

    Article  Google Scholar 

  13. Nguyen VB, English M (2017) Effects of cold roll dimpling process on mechanical properties of dimpled steel. Procedia Engineering 207:1290–5. https://doi.org/10.1016/j.proeng.2017.10.885

  14. Liu SZ, Minakawa K, Mcevily AJ (1985) The Effect of Cold Rolling on the Fatigue Properties of Ti-6AI-4V

  15. Lourenço NJ, Graça MLA, Franco LAL, Silva OMM (2008) Fatigue failure of a compressor blade. Eng Fail Anal 15:1150–1154. https://doi.org/10.1016/j.engfailanal.2007.11.006

    Article  Google Scholar 

  16. Zhang C, Chen H-P, Huang T-L (2018) Fatigue damage assessment of wind turbine composite blades using corrected blade element momentum theory. Measurement 129:102–11. https://doi.org/10.1016/j.measurement.2018.06.045

  17. Hirt G, Thome M (2008) Rolling of functional metallic surface structures. CIRP Annals 57:317–20. https://doi.org/10.1016/j.cirp.2008.03.034

  18. Romans T, Hirt G (2010) Rolling of drag reducing riblet-surfaces. Journal 3062. https://doi.org/10.2514/6.2010-3062

  19. Stille S, Pöplau J, Beck T, Bambach M, Hirt G, Singheiser L (2014) Very high cycle fatigue behavior of riblet structured Alclad 2024 thin sheets. Int J Fatigue 63:183–90. https://doi.org/10.1016/j.ijfatigue.2014.01.023

  20. Thome GM (2007) Large area rolling of functional metallic micro structures. Production process. Prod Eng Res Devel 1:351–6. https://doi.org/10.1007/s11740-007-0067-z

  21. Gao Z, Peng L, Yi P, Lai X (2013) An experimental investigation on the fabrication of micro/meso surface features by metallic roll-to-plate imprinting process. J Micro Nano-Manuf 1. https://doi.org/10.1115/1.4024985

  22. Gao Z, Peng L, Yi P, Lai X (2015) Grain and geometry size effects on plastic deformation in roll-to-plate micro/meso-imprinting process. J Mater Process Technol 219:28–41. https://doi.org/10.1016/j.jmatprotec.2014.12.005

  23. Klocke F, Feldhaus B, Mader S (2007) Development of an incremental rolling process for the production of defined riblet surface structures. Prod Eng Res Devel 1:233–237. https://doi.org/10.1007/s11740-007-0031-y

    Article  Google Scholar 

  24. Klocke F, Feldhaus B, Wegner H, Baecker V (2010) Rolling of defined riblet structures on compressor blades of Ti6Al4V. Steel Res Int 81:178–181. https://doi.org/10.1002/srin.201190002

    Article  Google Scholar 

  25. Terhorst M, Trauth D, Klocke F (2015) Riblet rolling on Ti6Al4V compressor blades. In: Tekkaya AE, Homberg W, Brosius A (eds) 60 Excellent inventions in metal forming. Springer Vieweg, Berlin, Heidelberg, pp 245–250

    Chapter  Google Scholar 

  26. Jili Y, Guangming Z, Mingkai D, Xujie G, Nana G, Zongshen W (2019) Simulation of incremental rolling process for a new roller profile. Forging & Stamping Technology 044:6–13

    Google Scholar 

  27. Gao X, Zhu G, Wang H, Guo N, Wang Z (2021) Research on micro riblets rolling process based on uncertainty analysis. Materials Today Communications 27:102302. https://doi.org/10.1016/j.mtcomm.2021.102302

  28. Denguir LA, Outeiro JC, Fromentin G, Vignal V, Besnard R (2017) A physical-based constitutive model for surface integrity prediction in machining of OFHC copper. J Mater Process Technol 248:143–60. https://doi.org/10.1016/j.jmatprotec.2017.05.009

  29. Lennart AM, Tobias W, Joerg R (2018) Numerical prediction of the notch effect of riblets on axial compressor blades. GPPS Montreal 2018 (GPPS-NA-2018), 7-9 May, Montreal Canada

Download references

Funding

This work was supported by the Natural Science Foundation of Shandong Province of China [Grant Numbers ZR2017MEE036 and ZR2017BEM003].

Author information

Authors and Affiliations

  1. School of Mechanical Engineering, Shandong University of Technology, 266 Xincun West Road, Zibo, 255000, People’s Republic of China

    Huihang Wang, Xujie Gao, Guangming Zhu, Zheng Chang, Nana Guo, Zongshen Wang & Lihua Zhu

  2. School of Computer Science and Technology, Shandong University of Technology, 266 Xincun West Road, Zibo, 255000, People’s Republic of China

    Huihang Wang, Xujie Gao, Guangming Zhu, Zheng Chang, Nana Guo, Zongshen Wang & Lihua Zhu

Authors
  1. Huihang Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Xujie Gao
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Guangming Zhu
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Zheng Chang
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Nana Guo
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Zongshen Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Lihua Zhu
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Huihang Wang: Methodology; Software; Writing, Original Draft; Writing, Review and Editing. Xujie Gao: Software; Validation; Writing, Original Draft. Guangming Zhu: Resources; Supervision. Zheng Chang: Resources; Supervision. Nana Guo: Investigation. Zongshen Wang: Investigation. Lihua Zhu: Investigation.

Corresponding author

Correspondence to Guangming Zhu.

Ethics declarations

Ethics approval

This chapter does not contain any studies with human participants or animals performed by any of the authors.

Consent to participate

Not applicable.

Consent for publication

All authors have read and agreed to the published version of the manuscript.

Competing interests

The authors declare no competing interests.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Wang, H., Gao, X., Zhu, G. et al. Process analysis and hole type optimization of micro-groove multi-pass rolling. Int J Adv Manuf Technol 119, 2201–2212 (2022). https://doi.org/10.1007/s00170-021-08338-y

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-021-08338-y

Keywords

Search

Navigation