Abstract
Surface texturing with micro-dimples is a known method for friction reduction under lubricated sliding contact, and various machining techniques have been researched and developed in order to fabricate micro-dimple patterns. However, previous fabrication methods possess several problems, such as causing thermal damage on the workpiece or limiting the available workpiece geometry. In micro ECM, micro features can be machined without any resulting thermal or mechanical damage. From this perspective, micro ECM has certain advantages over surface texturing. Also, micro ECM is applicable to non-planar workpieces. In this research study, micro ECM with microsecond pulses was applied in order to fabricate a micro-dimple pattern. The machining characteristics were investigated in fabricating micro dimples on AISI 440C specimen. On the basis of the experimental results, a Ø 300 μm dimple pattern was successively produced on the AISI 440C specimen. A friction test on the textured specimen was performed and compared with a non-textured specimen. The enhancement of frictional performance was successfully demonstrated experimentally.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
Abbreviations
- c :
-
double layer capacitance
- R s :
-
electrolyte resistance
- τ:
-
charging time constant
- ρ:
-
specific resistivity
- d :
-
distance between electrodes
- ϕ c :
-
charged potential of the double layer
- ϕ 0 :
-
applied potential
- t p :
-
pulse on-time
References
Bruzzone, A. A. G., Costa, H. L., Lonardo, P. M. and Lucca, D. A., “Advances in engineered surfaces for functional performance,” Cirp Ann-Manuf. Techn., Vol. 57, No. 2, pp. 750–769, 2008.
Etsion, I., Kligerman, Y. and Halperin, G., “Analytical and experimental investigation of laser-textured mechanical seal faces,” Tribology Trans., Vol. 42, No. 3, pp. 511–516, 1999.
Wang, Q. and Zhu, D., “Virtual texturing: Modeling the performance of lubricated contacts of engineered surfaces,” J. Tribol-T Asme, Vol. 127, No. 4, pp. 722–728, 2005.
Kim, D. E., Cha, K. H. and Sung, I. H., “Design of surface micro-structures for friction control in micro-systems applications,” Cirp Ann-Manuf. Techn., Vol. 51, No. 1, pp. 495–498, 2002.
Costa, H. L. and Hutchings, I. M., “Hydrodynamic lubrication of textured steel surfaces under reciprocating sliding conditions,” Tribol. Int., Vol. 40, No. 8, pp. 1227–1238, 2007.
Zhu, D., Qu, N. S., Li, H. S., Zeng, Y. B., Li, D. L. and Qian, S. Q., “Electrochemical micromachining of microstructures of micro hole and dimple array,” Cirp Ann-Manuf. Techn., Vol. 58, No. 1, pp. 177–180, 2009.
Wakuda, M., Yamauchi, Y., Kanzaki, S. and Yasuda, Y., “Effect of surface texturing on friction reduction between ceramic and steel materials under lubricated sliding contact,” Wear, Vol. 254, No. 3–4, pp. 356–363, 2003.
Etsion, I., “State of the art in laser surface texturing,” J. Tribol-T Asme, Vol. 127, No. 1, pp. 248–253, 2005.
Yi, W. and Dang-Sheng, X., “The effect of laser surface texturing on frictional performance of face seal,” J. Mater. Process Tech., Vol. 197, No. 1–3, pp. 96–100, 2008.
Kovalchenko, A., Ajayi, O., Erdemir, A., Fenske, G. and Etsion, I., “The effect of laser surface texturing on transitions in lubrication regimes during unidirectional sliding contact,” Tribol. Int., Vol. 38, No. 3, pp. 219–225, 2005.
Etsion, I. and Halperin, G., “A laser surface textured hydrostatic mechanical Seal,” Tribology Trans., Vol. 45, No. 3, pp. 430–434, 2002.
Brizmer, V., Kligerman, Y. and Etsion, I., “A laser surface textured parallel thrust bearing,” Tribology Trans., Vol. 46, No. 3, pp. 397–403, 2003.
Wang, X., Kato, K. and Adachi, K., “Running-in effect on the load-carrying capacity of a water-lubricated SiC thrust bearing,” Proceedings of the Institution of Mechanical Engineers, Part J: J. Eng. Tribol., Vol. 219, No. 2, pp. 117–124, 2005.
Kirchner, V., Cagnon, L., Schuster, R. and Ertl, G., “Electrochemical machining of stainless steel microelements with ultrashort voltage pulses,” Appl. Phys. Lett., Vol. 79, No. 11, pp. 1721–1723, 2001.
Schuster, R., Kirchner, V., Allongue, P. and Ertl, G., “Electrochemical micromachining,” Science, Vol. 289, No. 5476, pp. 98–101, 2000.
Park, M. S. and Chu, C. N., “Micro-electrochemical Machining Using Multiple Tool Electrodes,” J. Micromech. Microeng., Vol. 17, No. 8, pp. 1451–1457, 2007.
Shin, H. S., Kim, B. H. and Chu, C. N., “Analysis of the side gap resulting from micro electrochemical machining with a tungsten wire and ultrashort voltage pulses,” J. Micromech. Microeng., Vol. 18, No. 7, 075009, 2008.
Kim, B. H., Ryu, S. H., Choi, D. K. and Chu, C. N., “Micro Electrochemical Milling,” J. Micromech. Microeng., Vol. 15, No. 1, pp. 124–129, 2005.
Yang, I., Park, M. S. and Chu, C. N., “Micro ECM with Ultrasonic Vibrations Using a Semi-cylindrical Tool,” Int. J. Precis. Eng. Manuf., Vol. 10, No. 2, pp. 5–10, 2009.
Kim, B. H., Na, C. W., Lee, Y. S., Choi, D. K. and Chu, C. N., “Micro electrochemical machining of 3D micro structure using dilute sulfuric acid,” Cirp Ann-Manuf. Techn., Vol. 54, No. 1, pp. 191–194, 2005.
Wang, X., Kato, K., Adachi, K. and Aizawa, K., “Loads carrying capacity map for the surface texture design of SiC thrust bearing sliding in water,” Tribol. Int., Vol. 36, No. 3, pp. 189–197, 2003.
Wang, X. and Kato, K., “Improving the anti-seizure ability of SiC seal in water with RIE texturing,” Tribol. Lett., Vol. 14, No. 4, pp. 275–280, 2003.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Byun, J.W., Shin, H.S., Kwon, M.H. et al. Surface texturing by micro ECM for friction reduction. Int. J. Precis. Eng. Manuf. 11, 747–753 (2010). https://doi.org/10.1007/s12541-010-0088-y
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s12541-010-0088-y