Theoretical and Simulation Analysis on Fabrication of Micro-Textured Surface under Intermittent Cutting Condition by One-Dimensional Ultrasonic Vibration-Assisted Turning
Fabricating micro-textures with specific parameters (size, shape, and distribution) on the surface of mechanical components has the potential to improve the tribological performance. When the ultrasonic vibration is applied to depth direction of turning, the micro-textured surfaces with specific dim...
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MDPI AG
2022-02-01
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| Series: | Machines |
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| Online Access: | https://www.mdpi.com/2075-1702/10/3/166 |
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| author | Xianfu Liu Jianhua Zhang Li Li Weimin Huang |
| author_facet | Xianfu Liu Jianhua Zhang Li Li Weimin Huang |
| author_sort | Xianfu Liu |
| collection | DOAJ |
| description | Fabricating micro-textures with specific parameters (size, shape, and distribution) on the surface of mechanical components has the potential to improve the tribological performance. When the ultrasonic vibration is applied to depth direction of turning, the micro-textured surfaces with specific dimples can be generated in a simple and effective way. Under the intermittent cutting condition, the generation mechanism of the micro-textured surface, processed by this one-dimensional ultrasonic vibration-assisted turning (1D UVAT), was further carried out. A novel theoretical model was firstly proposed from the perspective of geometric kinematics, which can reveal the influence of three intersection states between the flank face and cutting trace (<i>η</i><sub>1</sub> < tan <i>α</i>, <i>η</i><sub>1</sub> > tan <i>α</i> > <i>η</i><sub>2</sub> and <i>η</i><sub>2</sub> > tan <i>α</i>) on the size, shape, and distribution of micro-dimples, generated under intermittent cutting conditions. Then, a simulation model was built to predict the surface topography and dimple profile under different processing parameters. The results show that the processing parameters, including clearance angle, spindle speed, and vibration amplitude, have an important influence on the intersection state. By choosing the proper clearance angle, spindle speed, or vibration amplitude, the different intersection states can be realized, and the corresponding size, shape, and distribution of micro-dimples will be changed accordingly. With the increase of the nose radius and feed rate, the dimple width and distance between adjacent dimples along feed direction can both increase accordingly. The simulation results not only confirm the feasibility of the proposed theoretical model, but also show that the discrete or continuous micro-dimples, with different sizes and specific shapes, can be controllably generated on cylindrical surface by 1D UVAT under intermittent cutting conditions. |
| first_indexed | 2024-03-09T13:33:31Z |
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| language | English |
| last_indexed | 2024-03-09T13:33:31Z |
| publishDate | 2022-02-01 |
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| spelling | doaj.art-bf2b681672fd428ba320366723f3db802023-11-30T21:15:45ZengMDPI AGMachines2075-17022022-02-0110316610.3390/machines10030166Theoretical and Simulation Analysis on Fabrication of Micro-Textured Surface under Intermittent Cutting Condition by One-Dimensional Ultrasonic Vibration-Assisted TurningXianfu Liu0Jianhua Zhang1Li Li2Weimin Huang3School of Mechanical Engineering, Shandong University of Technology, Zibo 255000, ChinaKey Laboratory of High Efficiency and Clean Mechanical Manufacture, Ministry of Education of China, School of Mechanical Engineering, Shandong University, Jinan 250061, ChinaSchool of Mechanical Engineering, Shandong University of Technology, Zibo 255000, ChinaCollege of Mechanical and Electronic Engineering, Shandong University of Science and Technology, Qingdao 266590, ChinaFabricating micro-textures with specific parameters (size, shape, and distribution) on the surface of mechanical components has the potential to improve the tribological performance. When the ultrasonic vibration is applied to depth direction of turning, the micro-textured surfaces with specific dimples can be generated in a simple and effective way. Under the intermittent cutting condition, the generation mechanism of the micro-textured surface, processed by this one-dimensional ultrasonic vibration-assisted turning (1D UVAT), was further carried out. A novel theoretical model was firstly proposed from the perspective of geometric kinematics, which can reveal the influence of three intersection states between the flank face and cutting trace (<i>η</i><sub>1</sub> < tan <i>α</i>, <i>η</i><sub>1</sub> > tan <i>α</i> > <i>η</i><sub>2</sub> and <i>η</i><sub>2</sub> > tan <i>α</i>) on the size, shape, and distribution of micro-dimples, generated under intermittent cutting conditions. Then, a simulation model was built to predict the surface topography and dimple profile under different processing parameters. The results show that the processing parameters, including clearance angle, spindle speed, and vibration amplitude, have an important influence on the intersection state. By choosing the proper clearance angle, spindle speed, or vibration amplitude, the different intersection states can be realized, and the corresponding size, shape, and distribution of micro-dimples will be changed accordingly. With the increase of the nose radius and feed rate, the dimple width and distance between adjacent dimples along feed direction can both increase accordingly. The simulation results not only confirm the feasibility of the proposed theoretical model, but also show that the discrete or continuous micro-dimples, with different sizes and specific shapes, can be controllably generated on cylindrical surface by 1D UVAT under intermittent cutting conditions.https://www.mdpi.com/2075-1702/10/3/166surface texturingultrasonic vibration-assisted turningintermittent cuttingmicro-dimplessimulation prediction |
| spellingShingle | Xianfu Liu Jianhua Zhang Li Li Weimin Huang Theoretical and Simulation Analysis on Fabrication of Micro-Textured Surface under Intermittent Cutting Condition by One-Dimensional Ultrasonic Vibration-Assisted Turning Machines surface texturing ultrasonic vibration-assisted turning intermittent cutting micro-dimples simulation prediction |
| title | Theoretical and Simulation Analysis on Fabrication of Micro-Textured Surface under Intermittent Cutting Condition by One-Dimensional Ultrasonic Vibration-Assisted Turning |
| title_full | Theoretical and Simulation Analysis on Fabrication of Micro-Textured Surface under Intermittent Cutting Condition by One-Dimensional Ultrasonic Vibration-Assisted Turning |
| title_fullStr | Theoretical and Simulation Analysis on Fabrication of Micro-Textured Surface under Intermittent Cutting Condition by One-Dimensional Ultrasonic Vibration-Assisted Turning |
| title_full_unstemmed | Theoretical and Simulation Analysis on Fabrication of Micro-Textured Surface under Intermittent Cutting Condition by One-Dimensional Ultrasonic Vibration-Assisted Turning |
| title_short | Theoretical and Simulation Analysis on Fabrication of Micro-Textured Surface under Intermittent Cutting Condition by One-Dimensional Ultrasonic Vibration-Assisted Turning |
| title_sort | theoretical and simulation analysis on fabrication of micro textured surface under intermittent cutting condition by one dimensional ultrasonic vibration assisted turning |
| topic | surface texturing ultrasonic vibration-assisted turning intermittent cutting micro-dimples simulation prediction |
| url | https://www.mdpi.com/2075-1702/10/3/166 |
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