Investigation of the application of a magnetic abrasive finishing process using an alternating magnetic field for finishing micro-grooves

A magnetic abrasive finishing process using an alternating magnetic field is proposed for the finishing of complex surfaces.In an alternating field,the periodic changes in current will cause the magnetic cluster used as a magnetic brush to fluctuate,which will not only continuously replace the abrasive particles in contact with the workpiece,but also periodically adjust the shape of the magnetic cluster to better fit the surface of the workpiece.In this paper,the influence of a combination of alternating and static magnetic fields on the magnetic field in the finishing area is analyzed.The feasibility of this process for finishing micro-grooves is investigated.Simulations and experimental measurements show that the combination of alternating and static magnetic fields can retain the advantages of the alternating field while increasing the magnetic flux density in the finishing area.The experimental results show that the process is feasible for finishing micro-grooves,with an excellent deburring effect on the groove edges.

Effect of geometric micro-groove texture patterns on tribological performance of stainless steel

This work describes an experimental investigation into the influence of geometric micro-groove texture patterns on the tribological performance of stainless steel.Five geometries were studied:one with untextured and four with micro-groove textured making parallel,triangular,square and hexagonal patterns.The micro-groove textures were produced using an MFT-20laser system as well as a two-step laser surface texturing(LST)process.Tribological performance was measured using a pin-on-disk tribometer.The investigation showed that the two-step LST process could fabricate high-precision micro-grooves.The experimental data indicated that the micro-groove textured surfaces achieved the lower frictional coefficients than the untextured surface and the geometric patterns had significantly affected the tribological properties of samples in both lubricated and unlubricated states.The results were analyzed from the lubricant supplying and fluid dynamic pressure effect under lubricated conditions as well as abrasive capture and remove under dry friction conditions.

Analysis of Collapse in Flattening a Micro-grooved Heat Pipe by Lateral Compression

The collapse of thin-walled micro-grooved heat pipes is a common phenomenon in the tube flattening process, which seriously influences the heat transfer performance and appearance of heat pipe. At present, there is no other better method to solve this problem. A new method by heating the heat pipe is proposed to eliminate the collapse during the flattening process. The effectiveness of the proposed method is investigated through a theoretical model, a finite element（FE） analysis, and experimental method. Firstly, A theoretical model based on a deformation model of six plastic hinges and the Antoine equation of the working fluid is established to analyze the collapse of thin walls at different temperatures. Then, the FE simulation and experiments of flattening process at different temperatures are carried out and compared with theoretical model. Finally, the FE model is followed to study the loads of the plates at different temperatures and heights of flattened heat pipes. The results of the theoretical model conform to those of the FE simulation and experiments in the flattened zone. The collapse occurs at room temperature. As the temperature increases, the collapse decreases and finally disappears at approximately 130 ℃ for various heights of flattened heat pipes. The loads of the moving plate increase as the temperature increases. Thus, the reasonable temperature for eliminating the collapse and reducing the load is approximately 130℃. The advantage of the proposed method is that the collapse is reduced or eliminated by means of the thermal deformation characteristic of heat pipe itself instead of by external support. As a result, the heat transfer efficiency of heat pipe is raised.

Effects of bending on heat transfer performance of axial micro-grooved heat pipe

Heat pipe is always bent in the typical application of electronic heat dissipation at high heat flux,which greatly affects its heat transfer performance. The capillary limit of heat transport in the bent micro-grooved heat pipes was analyzed in the vapor pressure drop,the liquid pressure drop and the interaction of the vapor with wick fluid. The bent heat pipes were fabricated and tested from the bending angle,the bending position and the bending radius. The results show that temperature difference and thermal resistance increase while the heat transfer capacity of the heat pipe decreases,with the increase of the bending angles and the bending position closer to the vapor section. However,the effects of bending radius can be ignored. The result agrees well with the predicted equations.

Droplet impact on regular micro-grooved surfaces

We have investigated experimentally the process of a droplet impact on a regular micro-grooved surface. The target surfaces are patterned such that micro-scale spokes radiate from the center, concentric circles, and parallel lines on the polishing copper plate, using Quasi-LIGA molding technology. The dynamic behavior of water droplets impacting on these structured surfaces is examined using a high-speed camera, including the drop impact processes, the maximum spreading diameters, and the lengths and numbers of fingers at different values of Weber number. Experimental results validate that the spreading processes are arrested on all target surfaces at low velocity. Also, the experimental results at higher impact velocity demonstrate that the spreading process is conducted on the surface parallel to the micro-grooves, but is arrested in the direction perpendicular to the micro-grooves. Besides, the lengths of fingers increase observably, even when they are ejected out as tiny droplets along the groove direction, at the same time the drop recoil velocity is reduced by micro-grooves which are parallel to the spreading direction, but not by micro-grooves which are vertical to the spreading direction.

Numerical Analysis of the Hydrodynamic Lubrication of Micro-grooved Friction Pair

A growing interest is given to the hydrodynamic lubricated friction pair with surface textured. Because of its relatively simple processing methods and low manufacturing costs,micro-groove has become the most valuable form of surface texture,and definitely has broad application prospects in mechanical engineering. Based on numerical simulation,the present study aims to examine the effects of surface forms and cross-section types of micro-groove on the hydrodynamic lubrication performance,and to find out the optimal structural parameter for designing logical micro-grooves. Different surface form and cross-section types are designed to maximize the texture hydrodynamic effect. The average pressure of such microgrooved surface is evaluated in detail,and the variation trends with changes of the length of micro-groove,lp,or the depth,hp,are discussed. The theoretical results show that micro-grooves with rational design contribute to the improvement of hydrodynamic lubrication performance of friction pair largely. For a specific micro-grooved friction pair,the optimal surface form and crosssection type make the lubrication performance best.

Influence of drawing process parameters on forming of micro copper tube with straight grooves

Using high-speed oil-filled spinning method,high quality micro copper tube with straight grooves（MCTSG） with an outer diameter of 6 mm was obtained.Then,MCTSG with an outer diameter of 3-6 mm was fabricated successfully by multi-pass drawing processing method.The influence of drawing parameters on the forming of micro straight grooves was investigated based on the forming mechanism.The results show that the values of groove depth and width decrease,while the wall thickness increases as the drawing diameter decreases.At the same time,the groove depth and width increase,while the wall thickness decreases as the die angle increases.The drawing force increases as the reduction increases.Excessive copper tube reduction may results in groove folding and segmental teeth.The drawing force decreases firstly and then increases with the increases in die angle.When the die angle α is 16°,the drawing force is the smallest,indicating 16° is the optimal angle.

Forming method of wick structure for heat column

The intensified boiling and condensation wick structures of heat column were designed and manufactured by ploughing-extrusion （P-E） machining method.The forming process and mechanism were analyzed.The results show that the P-E depth plays a decisive role in forming of wick structure.The larger the P-E depth is,the better the surface characteristics are.Only when the groove spacing is in a certain range,superior surface structure can be formed in the wick.The better enhancement boiling structure forms at P-E depth of 0.3 mm,ringed groove spacing of 0.4 mm,and interior angle of radial groove of 3°;the better enhancement condensation structure forms at P-E depth of 0.3 mm,ringed groove spacing of 0.4 mm,and axial grooves spacing of π/3 mm.

Micro-milling of Pyramid Structured Surface for Implant Application

Surface modification,as a promising approach to improve biocompatibility of biomaterials,has captured extensive close attention among many researchers.Here,micro-milling technology was used in constructing pyramid micro-structures on the surface of Ti-6Al-4Vimplant.Cutting parameters,including spindle speed,feed rate and depth of cut,were optimized to control the generation of burrs.In addition,low melting point alloy was selected to extend the boundary of the workpiece as supporting material to prevent the generation of top burrs.The surface topographies were characterized using scanning electron microscope and laser scanning microscope.Results showed that the dimension of burrs decreased with the decrease of depth of cut,and the size of burrs decreased with the increase of feed rate.Moreover,burrs nearly not appeared on both sides of the micro-grooves machined with low melting point alloy(LMPA)coating.Pyramid micro-structure on the workpiece surface was built successfully by combining optimized cutting parameters(S=35kr/min,Vf=60mm/min,ap=5μm)and LMPA coating.

High-quality micro-shape fabrication of monocrystalline diamond by nanosecond pulsed laser and acid cleaning

The flat plane of small surface roughness below 0.1μm average roughness was obtained for monocrystalline diamond by nanosecond pulsed laser irradiation of 1060 nm and post-process acid cleaning,at a laser fluence around the material removal threshold value.The glossy and flat plane at the bottom of the micro-groove was parallel to the top surface of the specimen,although the round beam of Gaussian mode was irradiated in the direction perpendicular to the top surface of specimen.The square beam of top-hat mode produced a shallower micro-groove with a wider,flatter bottom compared with the round beam in Gaussian mode.The creation method of the flat plane with small surface roughness was discussed in the arrangement strategy of linear micro-grooving by the square beam of top-hat mode.Normal side-by-side repetition of linear micro-grooving did not create a flat plane with constant depth.Therefore,a two-step scanning method was proposed in order to overcome the problem in the normal side-by-side repetition of liner micro-grooving.Non-removal areas were partly retained between the processing lines in the first step,and the laser scanning was conducted on the retained area in the second step.The newly proposed two-step scanning method was practical and useful to create a widely flat plane with small surface roughness,and the two-step scanning method provided superior control over the micro-groove depth.This proposed method can reduce the surface roughness in addition to the shape creation of monocrystalline diamond,and it can be used as a high-quality micro-shape fabrication method of monocrystalline diamond.

应用于高效雾气收集的润滑微沟槽锥

液滴在不对称一维表面的定向输送具有广泛应用,包括雾气收集、油水分离、海水淡化及传感等.液滴所受的驱动力和阻力共同作用决定液滴的运动性能,为提高液滴的运动性能,常见的策略是通过在运动方向引入各种不对称结构以增加驱动力,或者构建光滑表面以减少阻力.然而,到目前为止将增强驱动力和降低阻力同时整合到一个体系中的策略仍未见报道,这主要是由于传统的液体填充润滑表面所需的润滑油很难在物理或化学不对称的表面上稳定存在.本研究中,我们提出在具有微沟槽结构的锥表面接枝柔性聚合物分子刷,即通过协同表面结构和化学修饰来增大液滴在锥结构表面拉普拉斯驱动力并减小粘滞阻力.结果表明,与仅具有微沟槽结构的锥和仅具有聚合物分子刷的光滑锥相比,润滑微沟槽锥可显著提高液滴的运动性能,本研究为开发高效液滴运输智能表面提供了新思路.

U-shaped micro-groove fiber based on femtosecond laser processing for humidity sensing

A novel optical fiber sensor with a U-shaped micro-groove structure ablated by femtosecond laser on single-mode fiber for measuring air relative humidity(RH)is reported in this paper.In order to improve the accuracy of sensor,a graphene oxide(GO)/polyvinyl alcohol(PVA)composite film is coated on the surface of micro-groove structure.In the U-shaped micro-groove structure,the remaining core and micro-cavity in the micro-groove make up two major optical propagation paths,forming a Mach-Zehnder interferometer(MZI).The sensor has a good linear response within the RH range of 30%—85%,and the maximum sensitivity can reach 0.638 1 nm/%RH.The effect of temperature on the overall performance of the humidity sensor is also investigated.As a new type of all-fiber device,the sensor shows excellent sensitivity and stability.

Coupling effect of micro-textured tools and cooling conditions on the turning performance of aluminum alloy 6061

Micro-texturing has been widely proven to be an effective technology for achieving sustainable machining.However,the performance of micro-textured tools under different cooling conditions,especially their coupling effect on machined surface integrity,was scarcely reported.In this paper,the non-textured,linear micro-grooved,and curvilinear micro-grooved inserts were used to turn aluminum alloy 6061 under dry,emulsion,and liquid nitrogen cryogenic cooling conditions.The coupling effects of different micro-textures and cooling conditions on cutting force,cutting temperature,and machined surface integrity,including the surface roughness,work hardening,and residual stress,were revealed and discussed in detail.Results indicated that the micro-grooved tools,especially the curvilinear micro-grooved tools,not only reduced the cutting force and cutting temperature,but also improved the machined surface integrity.In addition,the micro-grooved tools can cooperate with the emulsion or liquid nitrogen to reduce the cutting force,cutting temperature,and improve the machined surface integrity generally,although the combination of emulsion cooling condition and micro-grooved tools generated negative coupling effects on cutting forces and surface work hardening.Especially,the combination of curvilinear micro-grooved cutting tools and cryogenic cooling condition resulted in the lowest cutting force and cutting temperature,which generated the surface with low roughness,weak work hardening,and compressive residual stress.

Operculum of a Water Snail is a Hydrodynamic Lubrication Sheet

Water snails developed a distinct appendage, the operculum, to better protect the body against predators. When the animal is active and crawling, part of the underside of the shell rests on the outer surface of the operculum. We observed the water snails （Pomacea canaliculata） spend -3 hours per day foraging, and the relative angular velocity between the shell and operculum can reach up to 10°·s^-1, which might inevitably lead to abrasion on the shell and operculum interface. However, by electron microscopy images, we found that the underside of the shell and outer surface of the operculum is not severely worn, which indicates that this animal might have a strategy to reduce wear. We discovered the superimposed rings distributed concentrically on the surface, which can generate micro-grooves for a hydrodynamic lubrication. We theoretically and experimentally revealed the mechanism of drag reduction combing the groove geometry and hydrodynamics. This textured operculum surface might provide a friction coefficient up to 0.012 as a stability-resilience, which protects the structure of the snail＇s shell and operculum. This mechanism might open up new paths for studies of micro-anti-wear structures used in liquid media.

Femtosecond laser-induced surface wettability modification of polystyrene surface

In this paper, we demonstrated a simple method to create either a hydrophilic or hydrophobic surface. With femtosecond laser irradiation at different laser parameters, the water contact angle (WCA) on polystyrene’s surface can be modified to either 12.7° or 156.2° from its original WCA of 88.2°. With properly spaced micro-pits created, the surface became hydrophilic probably due to the spread of the water droplets into the micro-pits. While with properly spaced micro-grooves created, the surface became rough and more hydrophobic. We investigated the effect of laser parameters on WCAs and analyzed the laser-treated surface roughness, profiles and chemical bonds by surface profilometer, scanning electron microscope (SEM) and X-ray photoelectron spectroscopy (XPS). For the laser-treated surface with low roughness, the polar (such as C—O, C=O, and O—C=O bonds) and non-polar (such as C—C or C—H bonds) groups were found to be responsible for the wettability changes. While for a rough surface, the surface roughness or the surface topography structure played a more significant role in the changes of the surface WCA. The mechanisms involved in the laser surface wettability modification process were discussed.

Drag reduction characteristics and flow field analysis of textured surface

A textured surface with a micro-groove structure exerts a distinct characteristic on drag reduction behavior. The fluid dynamic models of four textured surfaces are constructed in various profile geometries. Computational fluid dynamics is used to study the friction factors and drag reduction properties with various flow speeds on the textured surfaces. The friction coefficient varieties in the interface between the fluid and the textured surface are examined according to the simulation of the four geometries with V-shaped, saw tooth, rectangular, and semi-circular sections. The drag reduction efficiencies decrease with the increase in water velocity while it is less than a certain value. Moreover, the simulation results of the velocity, shear stress, energy, and turbulence effect on the V-shaped groove surface are presented in comparison with those of the smooth surface to illustrate the drag reduction mechanism. The results indicate that the peaks of the V-shaped grooves inhibit the lateral movement of the turbulent flow and generate the secondary vortex, which plays a key role in the impeding momentum exchange, thereby decreasing turbulent bursting intensity and reducing shear stress in the near-wall flow field. The kinetic energy and turbulence analysis shows that the vortex in the near-wall flow field on the textured surface is more stable compared to that on the smooth surface.