Recent advances in ultrasonic-assisted machining for the fabrication of micro/nano-textured surfaces

doi:10.1007/s11465-017-0422-5

Front. Mech. Eng.

2017, Vol. 12

Issue (1) : 33-45 https://doi.org/10.1007/s11465-017-0422-5

REVIEW ARTICLE

Recent advances in ultrasonic-assisted machining for the fabrication of micro/nano-textured surfaces

Shaolin XU¹,Tsunemoto KURIYAGAWA¹(

),Keita SHIMADA²,Masayoshi MIZUTANI²

¹. Division of Biomechanical Engineering, Graduate School of Biomedical Engineering, Tohoku University, Sendai 980-8579, Japan
². Department of Mechanical Systems Engineering, Graduate School of Engineering, Tohoku University, Sendai 980-8579, Japan

Download: PDF(1085 KB) HTML
Export: BibTeX | EndNote | Reference Manager | ProCite | RefWorks

Abstract

In this paper, the state of art of ultrasonic-assisted machining technologies used for fabrication of micro/nano-textured surfaces is reviewed. Diamond machining is the most widely used method in industry for manufacturing precision parts. For fabrication of fine structures on surfaces, conventional diamond machining methods are competitive by considering the precision of structures, but have limitations at machinable structures and machining efficiency, which have been proved to be partly solved by the integration of ultrasonic vibration motion. In this paper, existing ultrasonic-assisted machining methods for fabricating fine surface structures are reviewed and classified, and a rotary ultrasonic texturing (RUT) technology is mainly introduced by presenting the construction of vibration spindles, the texturing principles, and the applications of textured surfaces. Some new ideas and experimental results are presented. Finally, the challenges in using the RUT method to fabricate micro/nano-textured surfaces are discussed with respect to texturing strategies, machinable structures, and tool wear.

Keywords ultrasonic-assisted machining textured surface micro/nano-structures functional performance

Corresponding Author(s): Tsunemoto KURIYAGAWA

Just Accepted Date: 05 January 2017 Online First Date: 15 February 2017 Issue Date: 21 March 2017

Cite this article:

Shaolin XU,Tsunemoto KURIYAGAWA,Keita SHIMADA, et al. Recent advances in ultrasonic-assisted machining for the fabrication of micro/nano-textured surfaces[J]. Front. Mech. Eng., 2017, 12(1): 33-45.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-017-0422-5
https://academic.hep.com.cn/fme/EN/Y2017/V12/I1/33

Fig.1 Classification of machinable structures of diamond machining methods by shape and extension. Reprinted from Ref. [7] with permission from Elsevier

Fig.2 Schematics of four types of typical ultrasonic-assisted machining processes. (a) 1D ultrasonic-assisted grinding; (b) 1D ultrasonic-assisted milling; (c) 2D ultrasonic-assisted cutting; (d) 2D ultrasonic-assisted turning

Fig.3 Two typical structures fabricated with elliptical ultrasonic-assisted cutting technology. Reprinted from Ref. [18] with permission from Elsevier

Fig.4 1D and 2D ultrasonic-assisted turning processes for micro-texturing

Fig.5 Two typical structures fabricated with an elliptical ultrasonic texturing method with tools of different geometries. Reprinted from Ref. [15] with permission from Elsevier

Fig.6 Concept of 3D RUT method using a 3D rotary ultrasonic spindle

Fig.7 Possible machinable structures of the RUT method under vibration modes of (a) LV, (b) CV, and (c) HV

Fig.8 Two types of PZT systems for generating the two basic ultrasonic vibration modes: (a) LV mode, (b) BV mode

Fig.9 PZT system for generating elliptical or circular vibration in the transverse XY plane

Fig.10 PZT system used for manufacturing the 3D rotary ultrasonic spindle

Fig.11 Schematic of the construction of the 3D rotary ultrasonic spindle

Fig.12 Typical textured surfaces fabricated by UASG respectively under (a) LV, (b) CV, and (c) HV modes

Fig.13 Three typical cutting loci of the RUT processes. (a) LV, (b) CV, and (c) HV vibration modes

Fig.14 Typical textured surfaces fabricated by using RUT method under the (a) LV and (b) CV modes using electroplated single-point diamond tools

Fig.15 Two types of geometrically defined diamond tools for the RUT processes under the (a) LV and (b) CV vibration modes. Reprinted from Refs. [11,12] with permission from Springer

Fig.16 (a) Discrete steps of material removal processes in RUT and (b) simulated textured surfaces. Reprinted from Ref. [12] with permission from Springer

Fig.17 Typical textured surfaces fabricated by using the RUT method with geometrically defined diamond tools under (a) LV and (b) CV vibration modes. Reprinted from Refs. [11,12] with permission from Springer

Fig.18 A textured surfaces and it representative water contact angles, possessing directional wetting properties. Reprinted from Refs. [12] with permission from Springer

1	Evans C J, Bryan J B. “Structured”, “textured” or “engineered” surfaces. CIRP Annals—Manufacturing Technology, 1999, 48(2): 541–556 doi:10.1016/S0007-8506(07)63233-8
2	Bauer S, Schmuki P, von der Mark K, Engineering biocompatible implant surfaces: Part I: Materials and surfaces. Progress in Materials Science, 2013, 58(3): 261–326 doi:10.1016/j.pmatsci.2012.09.001
3	Chung K K, Schumacher J F, Sampson E M, Impact of engineered surface microtopography on biofilm formation of Staphylococcus aureus. Biointerphases, 2007, 2(2): 89–94 https://doi.org/10.1116/1.2751405
4	Tsipenyuk A, Varenberg M. Use of biomimetic hexagonal surface texture in friction against lubricated skin. Journal of the Royal Society Interface, 2014, 11(94): 20140113 https://doi.org/10.1098/rsif.2014.0113
5	Bhushan B. Biomimetics: Lessons from nature—An overview. Philosophical Transactions. Series A, Mathematical, Physical and Engineering Science, 2009, 367(1893): 1445–1486 https://doi.org/10.1098/rsta.2009.0011
6	Bruzzone A A G, Costa H L, Lonardo P M, Advances in engineered surfaces for functional performance. CIRP Annals—Manufacturing Technology, 2008, 57(2): 750–769 https://doi.org/10.1016/j.cirp.2008.09.003
7	Brinksmeier E, Gläbe R, Schӧnemann L. Review on diamond-machining processes for the generation of functional surface structures. CIRP Journal of Manufacturing Science and Technology, 2012, 5(1): 1–7 https://doi.org/10.1016/j.cirpj.2011.10.003
8	Xu S, Nishikawa C, Shimada K, Surface textures fabrication on zirconia ceramics by 3D ultrasonic vibration assisted slant feed grinding. Advanced Materials Research, 2013, 797: 326–331
9	Xu S, Shimada K, Mizutani M, Surface texturing and wettability evaluation of zirconia ceramics. In: Proceedings of International Conference on Leading Edge Manufacturing in 21st Century: LEM21. 2013, 7: 208–213
10	Xu S, Shimada K, Mizutani M, Fabrication of hybrid micro/nano-textured surfaces using rotary ultrasonic machining with one-point diamond tool. International Journal of Machine Tools and Manufacture, 2014, 86: 12–17 https://doi.org/10.1016/j.ijmachtools.2014.06.005
11	Xu S, Shimada K, Mizutani M, Development of a novel 2D rotary ultrasonic texturing technique for fabricating tailored structures. International Journal of Advanced Manufacturing Technology, 2016 (in press)
12	Xu S, Shimada K, Mizutani M, Analysis of machinable structures and their wettability of rotary ultrasonic texturing method. Chinese Journal of Mechanical Engineering, 2016, 29(6): 1187–1192 https://doi.org/10.3901/CJME.2016.0910.112
13	Denkena B, Kästner J, Wang B. Advanced microstructures and its production through cutting and grinding. CIRP Annals—Manufacturing Technology, 2010, 59(1): 67–72 https://doi.org/10.1016/j.cirp.2010.03.066
14	Guo P, Ehmann K F. Development of a tertiary motion generator for elliptical vibration texturing. Precision Engineering, 2013, 37(2): 364–371 https://doi.org/10.1016/j.precisioneng.2012.10.005
15	Guo P, Ehmann K F. An analysis of the surface generation mechanics of the elliptical vibration texturing process. International Journal of Machine Tools and Manufacture, 2013, 64: 85–95 https://doi.org/10.1016/j.ijmachtools.2012.08.003
16	Ahmed S A, Hoon Ko J, Subbiah S, Microtexture generation using controlled chatter machining in ultraprecision diamond turning. Journal of Micro and Nano-Manufacturing, 2015, 3(2): 021002 doi:10.1115/1.4029610
17	Brehl D E, Dow T A. Review of vibration-assisted machining. Precision Engineering, 2008, 32(3): 153–172 https://doi.org/10.1016/j.precisioneng.2007.08.003
18	Suzuki N, Yokoi H, Shamoto E. Micro/nano sculpturing of hardened steel by controlling vibration amplitude in elliptical vibration cutting. Precision Engineering, 2011, 35(1): 44–50 https://doi.org/10.1016/j.precisioneng.2010.09.006
19	Brehl D E, Dow T A. 3-D microstructure creation using elliptical vibration-assisted machining. In: Proceedings of ASPE Spring Topical Meeting on Vibration Assisted Machining Technology. Raleigh, 2007, 21–26
20	Aurich J C, Egnmann J, Schueler G M, Micro grinding tool for manufacture of complex structures in brittle materials. CIRP Annals —Manufacturing Technology, 2009, 58(1): 311–314 https://doi.org/10.1016/j.cirp.2009.03.049
21	Sugai T. Study on ultrasonic vibration cutting. Dissertation for the Master’s Degree. Sendai: Tohoku University, 2014
22	Shimada K. Study on Vibration Grinding. Dissertation for the Doctoral Degree. Sendai: Tohoku University, 2012
23	Denkena B, Biermann D. Cutting edge geometries. CIRP Annals—Manufacturing Technology, 2014, 63(2): 631–653 https://doi.org/10.1016/j.cirp.2014.05.009
24	Zhu Z, To S, Zhang S. Theoretical and experimental investigation on the novel end-fly-cutting-servo diamond machining of hierarchical micro-nanostructures. International Journal of Machine Tools and Manufacture, 2015, 94: 15–25 doi:10.1016/j.ijmachtools.2015.04.002
25	Harano K, Satoh T, Sumiya H. Cutting performance of nano-polycrystalline diamond. Diamond and Related Materials, 2012, 24: 78–82 https://doi.org/10.1016/j.diamond.2011.11.005

[1]	Dazhi WANG, Xiaojun ZHAO, Yigao LIN, Tongqun REN, Junsheng LIANG, Chong LIU, Liding WANG. Fabrication of micro/nano-structures by electrohydrodynamic jet technique[J]. Front. Mech. Eng., 2017, 12(4): 477-489.

Viewed

Full text

Abstract

Cited

Shared

Discussed