Economical and Ecological Benefits of Process-Integrated Surface Structuring

Thome, Mario

doi:10.4028/www.scientific.net/kem.344.939

Cited by 7 publications

(5 citation statements)

References 4 publications

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“…The strain values were evaluated from the thickness reductions in the Al sheets using ϵ = ln (h ms /h dp ), where h dp is the average thickness of the deformed metallic sheet. Figure 8(a) shows the flow stress and strain data, and the curve fitted assuming shifted power-law hardening σ = a(ϵ-b) c [39,43,44]. The constants a, b and c and the equation are displayed in the inset of figure 8(a).…”

Section: Finite Element Modelling Of Formation Of Micro-dimplesmentioning

confidence: 99%

“…The roller and blank were driven with angular and linear velocities in accordance with the experiments. The coefficient of friction between the aluminium sheet and steel in the FE simulations was specified as 0.2 [35,39,44,46]. The flow stress data following the power-law behaviour in figure 8(a) was used in a tabular form to define the material behaviour in numerical simulations.…”

Section: Finite Element Modelling Of Formation Of Micro-dimplesmentioning

confidence: 99%

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Wire mask assisted rolling as a cost-effective method for high-throughput surface micro-texturing

Gaddam

Prabhakaran

Agrawal

et al. 2020

J. Micromech. Microeng.

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Micro-dimples are a specific class of surface textures that are ubiquitous in a wide range of applications where functionalities such as wetting, hydrodynamic drag reduction, and sliding friction reduction are needed. However, fabrication of the micro-dimples through the existing manufacturing techniques involves the use of complex equipment and requires relatively long cycle times. Consequently, we report here proof-of-concept of a method that enables in fabricating micro-dimples in a facile and fast manner. The industrial sieve wire masks were employed to deform metallic sheets at discrete locations by the cold rolling process. The geometry of projections on the wire masks allowed the formation of ellipsoid shaped micro-dimples in two distinct patterns on metallic sheets. The finite element modelling of process-material interactions was accurately predicted the formation of micro-dimples under different reduction ratios. We also demonstrate that the micro-dimples can be easily replicated on polymer surfaces using textured metallic moulds, which facilitates low-cost mass production in microfluidic applications. The presence of micro-dimples on polymer surfaces has led to an increase in water contact angles and resulted in a substantial drag reduction in microchannels. From the tribological viewpoint, the obtained patterns and surface area fractions of the micro-dimples are attractive. These findings provide a promising way to create textured surfaces in an economical manner, with functionalities suitable for microfluidic and tribological devices.

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Section: Finite Element Modelling Of Formation Of Micro-dimplesmentioning

confidence: 99%

Section: Finite Element Modelling Of Formation Of Micro-dimplesmentioning

confidence: 99%

Wire mask assisted rolling as a cost-effective method for high-throughput surface micro-texturing

Gaddam

Prabhakaran

Agrawal

et al. 2020

J. Micromech. Microeng.

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“…Bringing riblet structures into metal surfaces has been investigated in previous publications [7,8,9,10,11,12]. As riblet efficiency has to be in accordance with producibility, semi-circular riblets seem to be a reasonable choice (Fig.…”

Section: State Of the Artmentioning

confidence: 99%

The Influence of Process Parameters on the Forming of Riblets during Riblet Rolling

Pöplau

Stille

Romans

et al. 2014

KEM

Self Cite

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In aeronautics, economic and environmental aspects become increasingly important. As those are very much influenced by the frictional drag of the airplane, a reduction of skin friction which causes a major portion of total aerodynamic drag is desirable. One possible approach for passive drag reduction is the application of riblets small longitudinal grooves orientated in flow direction. Through an adapted rolling process, riblets can be brought into metal sheets on a large scale. For this process a thin high-strength steel wire is wound around a work roll to structure it with the negative riblet imprint. In a subsequent step the riblet profile is rolled into the sheet material. Different parameters can influence the process and the quality of the resulting riblet structure. Those parameters that depend on the sheets sheet thickness, material strength, and composition of the sheet are discussed in this paper. Form filling is used as an indicator for riblet quality. It is found that decreasing sheet thickness is beneficial for form filling, but a process dependent minimum sheet thickness exists for which this effect will reverse. Material strength is found to have a much smaller influence on form filling. Nevertheless, harder alloys seem to need a slightly smaller thickness reduction, but higher rolling forces and pressures to achieve desired form filling. Using clad instead of bare materials has a positive influence on form filling and riblet structuring. Furthermore, riblet rolling does not reduce the fatigue strength of the clad material.

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“…An enhancement of product functionality had been developed by specific functional surface structures with micro-structure. 1,2 Micro-structured surface can also improve ecologic aspects in production processes and reduce the resistance of material, improving wear resistance and mechanical properties. Several authors [3][4][5] reported using special biological surface microstructures with super-oleophobic characteristics, solved the problems associated with oil adhering to pipeline surfaces, and subsequently contributed to reducing the marine oil pollution.…”

Section: Introductionmentioning

confidence: 99%

“…With the development of machining, many high precision microstructures on the rolls can be machined. 2,19 During rolling, it is difficult for aluminum alloy sheet having poor flowability because the literature 18 showed riblet form filling up to 70%, that required rolling high quality filling grooves on the surface improve furtherly. In order to meet the requirements of the better grooves on the surface, it is necessary to improve the flowability of aluminum alloy.…”

Section: Introductionmentioning

confidence: 99%

Influence of heated rolling micro-groove on surface of sheet metal

2017

Advances in Mechanical Engineering

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Sheet metal with micro-groove on its surface has following advantages, such as lightweight, high wear resistance, and drag function, and is hence widely used in various applications. Currently, there are a series of methods to process micro-groove, but those methods are not used in mass production. In this article, roll-to-roll sheet forming method preheated to elevated temperatures has been discussed and shown to produce micro-structure with better shape and height, in addition to aiding the possibility of continuous production. The influence of rolling micro-groove is studied numerically using the software Deform-3D. Temperature, grain size, geometry, rolling load, size, and height of microgrooves have been discussed. The results show that the temperatures, widths of the groove, and radius of top and bottom fillets have significant influence on the forming process. At the same time, the experiments prove the feasibility of heated rolling micro-groove on surface of sheet metal.

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Economical and Ecological Benefits of Process-Integrated Surface Structuring

Cited by 7 publications

References 4 publications

Wire mask assisted rolling as a cost-effective method for high-throughput surface micro-texturing

Wire mask assisted rolling as a cost-effective method for high-throughput surface micro-texturing

The Influence of Process Parameters on the Forming of Riblets during Riblet Rolling

Influence of heated rolling micro-groove on surface of sheet metal

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