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Research Papers

Fast Generation of Micro-Channels on Cylindrical Surfaces by Elliptical Vibration Texturing

[+] Author and Article Information
Ping Guo

Department of Mechanical Engineering,
Northwestern University,
2145 Sheridan Road,
Evanston, IL 60208
e-mail: pingguo2009@u.northwestern.edu

Yong Lu

State Key Laboratory of Automotive
Safety and Energy,
Tsinghua University,
Beijing 100084, China
e-mail: luy05@mails.tsinghua.edu.cn

Pucheng Pei

State Key Laboratory of Automotive
Safety and Energy,
Tsinghua University,
Beijing 100084, China
e-mail: pchpei@mail.tsinghua.edu.cn

Kornel F. Ehmann

Department of Mechanical Engineering,
Northwestern University,
2145 Sheridan Road,
Evanston, IL 60208
e-mail: k-ehmann@northwestern.edu

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received July 1, 2013; final manuscript received March 1, 2014; published online May 21, 2014. Assoc. Editor: Tony Schmitz.

J. Manuf. Sci. Eng 136(4), 041008 (May 21, 2014) (10 pages) Paper No: MANU-13-1265; doi: 10.1115/1.4027126 History: Received July 01, 2013; Revised March 01, 2014

Micro-structured surfaces are assuming an ever-increasing role since they define the ultimate performance of many industrial components and products. Micro-channels, in particular, have many potential applications in micro-fluidic devices, micro heat exchangers, and friction control. This paper proposes an innovative vibration-assisted machining method to generate micro-channels on the external surface of a cylinder. This method, referred to as elliptical vibration texturing, was originally developed by the authors to generate dimple patterns. It uses the modulation of the depth-of-cut by tool vibrations to create surface textures. The most promising features of the proposed method are its high efficiency, low cost, and scalability for mass production. It is shown that with proper combinations of the process parameters the created dimples start to overlap and form channels. An analytical model is established to predict channel formation with respect to the overlapping ratios of the dimples. Channel formation criteria and expressions for channel geometries are given along with a channel generation map that relates channel geometry to the process parameters. Experimental results are given to verify the model. A further example of micro-pattern generation is also given to showcase the flexibility of the process.

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Figures

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Fig. 1

Schematic of the elliptical vibration texturing process

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Fig. 2

3D model of the tertiary motion generator

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Fig. 3

Experimental setup

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Fig. 4

Dimple array geometry definition

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Fig. 5

Channel generation schematics and simulated channels in different modes

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Fig. 6

Effective feature depth and dimple length diagram

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Fig. 7

Channel formation: (a) dimple overlap diagram (b) well-formed channels (c) small principal overlapping ratio and (d) non-zero minor overlapping ratio

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Fig. 8

Schematic of "multi-threaded" spiral channels

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Fig. 9

Generalized channel generation map

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Fig. 10

Channel generation map

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Fig. 11

Feasible region for channel generation

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Fig. 12

Comparison between experiments and simulation of surface topography and profiles for dimple arrays

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Fig. 13

Examples of generated and simulated surface topography of micro channels: (a) Mode I channels (N = 20,044 RPM, feed = 10 μm, DOC = 3 μm), (b) Mode II channels (N = 20,072 RPM, feed = 10 μm, DOC = 3 μm), and (c) unsuccessful Mode III channels (N = 19,906 RPM, feed = 10 μm, DOC = 3 μm)

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Fig. 15

Demonstration of micro-pattern generation

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