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Manufacturing of durable tribological surface by grinding process

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Abstract

In the scenario of the modern manufacturing process, with the current demand for products and processes that require high-tech technology, the performance of a component is of great interest. In surface engineering, for example, the structured surface could significantly affect performance improvements. Micro- and nano-scale surface roughness plays the main role in the structured surfaces by determining the kinematics involved in this event. Among various features, the hydrophobic structured surface as a tribo-surface has found extensive applications, including drag reduction, improving heat transfer, anti-corrosion properties (anti-fogging and anti-icing), oil–water separation membrane, freshwater production, etc. Nevertheless, most available methods are two-step, complex, expensive, and questionable in terms of human health. In the present study, a new grinding method was proposed to manufacture structured surfaces with hydrophobic properties and drag reduction. The random distribution of the diamond particles was arranged on the wheel surface. They were placed in the predetermined location by a drilled thin polyethylene mask and a neodymium magnet as a non-contact external fixture. The Scanning Electron Microscope images revealed that the modified wheel resulted in a structured surface with continuous and discontinuous scratches. Shark skin texture as a unique topography was obtained by changing the cutting parameters. The results of the drag test showed that it was reduced by 20 to 30% for the Reynolds of 400 to 800. Changing the surface wetting regime from hydrophilicity to hydrophobicity was the main reason for drag reduction of the structured surfaces compared to the unstructured ones. According to the experiments, the contact angle improvement of the structured sample was around 361%. The formation of accumulated materials on the surface peaks during ductile material removal increased the scratch real depth from its nominal value. This phenomenon led to development of large air pads into scratches, which enhanced the hydrophobicity.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Amirkabir University of Technology, Tehran, Iran

    Seyed Hasan Musavi, Hamed Adibi & Seyed Mehdi Rezaei

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  1. Seyed Hasan Musavi
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  2. Hamed Adibi
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  3. Seyed Mehdi Rezaei
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Contributions

The research results in this work were presented in the Ph.D. thesis of Mr. Musavi. S.H. Musavi designed and performed experiments, analyzed data, and wrote the paper. Dr. Adibi and Dr. Rezaei also acted as the supervisors of Mr. Musavi. All authors have read and agreed to the published version of the manuscript.

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Correspondence to Hamed Adibi.

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Highlights

• A new technique for manufacturing structured grinding wheels with diamond abrasive particles was proposed.

• Tribological surfaces were manufactured by grinding technique with continuous and discontinuous scratches.

• Up to 30% improvement was recorded in the drag reduction for the structured surface.

• Up to 360% improvement was recorded in the hydrophobicity for the structured surface.

• Over time, the tribological properties of the surface have not decreased significantly, which indicates the durable properties of the produced surfaces.

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Musavi, S.H., Adibi, H. & Rezaei, S.M. Manufacturing of durable tribological surface by grinding process. Int J Adv Manuf Technol 122, 3393–3410 (2022). https://doi.org/10.1007/s00170-022-10104-7

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  • DOI: https://doi.org/10.1007/s00170-022-10104-7

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