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Study on the fabrication of micro-textured end face in one-dimensional ultrasonic vibration–assisted turning

  • Xianfu Liu
  • Xiangyi Hu
  • Jianhua ZhangEmail author
  • Debao Wu
ORIGINAL ARTICLE
  • 69 Downloads

Abstract

Through fabricating the micro-textures to improve surface property, the surface texturing technology has become a widely used way to prepare the functionalized surface. This study proposed a surface texturing method of one-dimensional ultrasonic vibration–assisted turning to generate micro-textured end face. The generation principle for the micro-textured end face was presented through the description of cutting conditions, the theoretical analysis of textured features, and the simulation prediction of surface topography. The polycrystalline diamond cutting tools with different clearance angles (7° and 20°) and nose radiuses (400 μm, 200 μm, and 100 μm) were used in the experimental tests to investigate the influence of tool geometry on the micro-dimple features. The results show that the micro-dimples with different sizes and shapes can be successfully fabricated on the end face of Copper 1100. Same as the theoretical analysis and simulation prediction, through changing the cross-sectional profile of dimple along cutting direction, the clearance angle and the radius of observed point were verified to play a key role in the shape of micro-dimple. The oval-like dimples and the scale-like dimples can be respectively manufactured under the different intersection states between the flank face and the cutting trace. It was also confirmed that by choosing proper nose radius and the corresponding feed rate, the textured surface covered by micro-dimples of different widths can be generated. This texturing method used for fabricating the micro-textured end face was verified to be feasible and efficient, which laid a foundation for further research on the application of the textured surface.

Keywords

Surface texturing Ultrasonic vibration–assisted turning Micro-textured end face Dimples Tool geometry 

Abbreviations

n

Spindle speed

A

Amplitude

DOC

Depth of cut

D12

Distance between point B1 and B2

N12

Number of the revolutions of workpiece from B1 to B2

S

Distance between two adjacent micro-dimples in feed direction

f

Feed rate

vc

Instantaneous cutting speed

R

Radius corresponding to the point on end face

R1

Radius of the point B1 on end face

R2

Radius of the point B2 on end face

R3

Radius of the point B3 on end face

R4

Radius of the point B4 on end face

d

Distance of adjacent two dimples in cutting direction

fus

Ultrasonic vibration frequency

w

Width of dimple caused by the ultrasonic vibration

Rc

Nose radius of cutting tool

α

Clearance angle of tool

θ

Angle between CG and FG

η

Intersecting ratio

φ

Intersection angle

h

Depth of dimple

d1

One part of distance of adjacent two dimples in cutting direction

d2

Another part of distance of adjacent two dimples in cutting direction

t1

Time taken for the tool from point C to point E

LST

Laser surface texturing

ECM

Electrochemical machining

AJM

Abrasive-jet machining

UVD

Ultrasonic vibration device

CNC

Computerized numerical controlled

Notes

Funding information

This work was supported by the National Natural Science Foundation of China (NSFC), No. 51475275.

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Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2019

Authors and Affiliations

  • Xianfu Liu
    • 1
    • 2
  • Xiangyi Hu
    • 1
    • 2
  • Jianhua Zhang
    • 1
    • 2
    Email author
  • Debao Wu
    • 1
    • 2
  1. 1.Key Laboratory of High Efficiency and Clean Mechanical Manufacture, Ministry of Education of China, School of Mechanical EngineeringShandong UniversityJinanChina
  2. 2.National Demonstration Center for Experimental Mechanical Engineering Education, School of Mechanical EngineeringShandong UniversityJinanChina

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