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

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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.

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Abbreviations

n :

Spindle speed

A :

Amplitude

DOC:

Depth of cut

D 12 :

Distance between point B1 and B2

N 12 :

Number of the revolutions of workpiece from B1 to B2

S :

Distance between two adjacent micro-dimples in feed direction

f :

Feed rate

v c :

Instantaneous cutting speed

R :

Radius corresponding to the point on end face

R 1 :

Radius of the point B1 on end face

R 2 :

Radius of the point B2 on end face

R 3 :

Radius of the point B3 on end face

R 4 :

Radius of the point B4 on end face

d :

Distance of adjacent two dimples in cutting direction

f us :

Ultrasonic vibration frequency

w :

Width of dimple caused by the ultrasonic vibration

R c :

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

d 1 :

One part of distance of adjacent two dimples in cutting direction

d 2 :

Another part of distance of adjacent two dimples in cutting direction

t 1 :

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

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Funding

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

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Authors and Affiliations

  1. Key Laboratory of High Efficiency and Clean Mechanical Manufacture, Ministry of Education of China, School of Mechanical Engineering, Shandong University, Jinan, 250061, China

    Xianfu Liu, Xiangyi Hu, Jianhua Zhang & Debao Wu

  2. National Demonstration Center for Experimental Mechanical Engineering Education, School of Mechanical Engineering, Shandong University, Jinan, 250061, China

    Xianfu Liu, Xiangyi Hu, Jianhua Zhang & Debao Wu

Authors
  1. Xianfu Liu
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  2. Xiangyi Hu
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  4. Debao Wu
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Correspondence to Jianhua Zhang.

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Liu, X., Hu, X., Zhang, J. et al. Study on the fabrication of micro-textured end face in one-dimensional ultrasonic vibration–assisted turning. Int J Adv Manuf Technol 105, 2599–2613 (2019). https://doi.org/10.1007/s00170-019-04535-y

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  • DOI: https://doi.org/10.1007/s00170-019-04535-y

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