Manufacture of functional surfaces through combined application of tool manufacturing processes and Robot Assisted Polishing

Eriksen, Rasmus Solmer; Arentoft, Mogens; Grønbæk, J.; Bay, Niels

doi:10.1016/j.cirp.2012.03.020

Cited by 25 publications

(14 citation statements)

References 6 publications

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“…In order to ensure the successful design of such tailored tool surfaces, it is important to understand the influence of surface texture parameters on friction and lubrication in metal forming. Manufacturing of the tailored tool surfaces into a table mountain-like structure with flat plateaus and neighbouring flat bottomed valleys can be obtained by combined grinding, milling, and polishing of tools [12,13]. A small pocket angle towards the workpiece surface facilitates escape of the trapped lubricant in the pockets, which increases the tool life [14].…”

Section: Introductionmentioning

confidence: 99%

The Influence of Tool Texture on Friction and Lubrication in Strip Reduction Testing

2017

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While texturing of workpiece surfaces to promote lubrication in metal forming has been applied for several decades, tool surface texturing is rather new. In the present paper, tool texturing is studied as a method to prevent galling. A strip reduction test was conducted with tools provided with shallow, longitudinal pockets oriented perpendicular to the sliding direction. The pockets had small angles to the workpiece surface and the distance between them were varied. The experiments reveal that the distance between pockets should be larger than the pocket width, thereby creating a topography similar to flat table mountains to avoid mechanical interlocking in the valleys; otherwise, an increase in drawing load and pick-up on the tools are observed. The textured tool surface lowers friction and improves lubrication performance, provided that the distance between pockets is 2-4 times larger than the pocket width. Larger drawing speed facilitates escape of the entrapped lubricant in the pockets. Testing with low-to-medium viscosity oils leads to a low sheet roughness on the plateaus, but also local workpiece material pick-up on the tool plateaus. Large lubricant viscosity results in higher sheet plateau roughness, but also prevents pick-up and galling.

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Section: Introductionmentioning

confidence: 99%

The Influence of Tool Texture on Friction and Lubrication in Strip Reduction Testing

2017

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“…A great number of surface texturing techniques are available for texturing of hard tool materials such as combined milling, grinding and manual polishing [12], chemical etching [15], rolling ball indentation [17] and laser radiation [18][19]. In this study, high speed, hard machining combined with manual polishing was chosen.…”

Section: Manufacture Of Surface Texturesmentioning

confidence: 99%

“…In order to ensure successful design of such tailored tool surfaces it is important to understand the influence of surface texture parameters on friction and lubrication in metal forming. Manufacturing of the tailored tool surfaces into a table mountain like 2 of 11 structure with flat plateaus and neighbouring flat bottomed valleys can be obtained by combined grinding, milling and polishing of tools [12][13]. A small pocket angle towards the workpiece surface facilitates escape of the trapped lubricant in the pockets, which increases the tool life [14].…”

Section: Introductionmentioning

confidence: 99%

The Influence of Tool Texture on Friction and Lubrication in Strip Reduction Testing

Sulaiman¹,

Christiansen²,

Bay³

2016

Preprint

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While texturing of workpiece surfaces to promote lubrication in metal forming has been applied for several decades tool surface texturing is rather new. In the present paper tool texturing is studied as a method to prevent galling. Adopting a strip reduction test longitudinal pocket geometries oriented perpendicular to the sliding direction, with shallow pocket depth, small pocket angle to the workpiece surface and varying distance between pockets are investigated. The experiments reveal that the distance between pockets should be larger than the pocket width thereby creating a topography similar to flat table mountains to avoid mechanical interlocking in the valleys; otherwise an increase in drawing load and pick-up on the tools is observed. The textured tool surface lowers friction and improves lubrication performance provided that the distance between pockets is 2-4 times larger than the pocket width. Larger drawing speed facilitates escape of the entrapped lubricant in the pockets. Testing with low to medium viscosity oils leads to a low sheet roughness on the plateaus but also local workpiece material pick-up on the tool plateaus. Large lubricant viscosity results in higher sheet plateau roughness but also prevents pick-up and galling.

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“…Recently, a novel typology of textured surfaces has been introduced: the so-called multifunctional surfaces (MUFU) [18,19]. Similarly to plateau-honed surfaces, multifunctional surfaces are produced through a two-step process generating a surface with bearing capabilities and the ability of providing extra-lubrication.…”

Section: Introductionmentioning

confidence: 99%

“…Yet, differently from plateau-honing, the pre-machining is a hardturning operation, which provides a deterministic distribution of surface peaks and valleys rather than a stochastic one. The finishing process is a Robot Assisted Polishing (RAP) operation performed on a machine developed by the Danish company Strecon A/S [19]. The RAP machine gradually removes the peaks of the original turned surface yielding a surface with a certain degree of bearing area and a deterministic distribution of lubricant channels (Fig.…”

Section: Introductionmentioning

confidence: 99%

Testing of Newly Developed Functional Surfaces Under Pure Sliding Conditions

Godi

Mohaghegh

Grønbæk³

et al. 2013

Tribol Lett

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The employment of surface texturing for improved tribological contacts has spread over the years. The possibilities of designing and manufacturing textured surfaces with predetermined geometries have multiplied as well as the need of performing experimental laboratory tests before applying the surfaces in an industrial context. In this paper a number of experimental tests were performed using a novel test rig, called Axial Sliding Test, simulating the contact of surfaces under pure sliding conditions. The aim of the experiments is to evaluate the frictional behavior of a new typology of textured surfaces, the so-called multifunctional surfaces characterized by a plateau area able to bear loads and a deterministic pattern of lubricant pockets. Six surface typologies, namely three multifunctional and three machined using classical processes were chosen to slide against a mirror-polished counterpart. A number of experiments were carried out at different normal pressures employing for all specimens the same reciprocating movement and the same lubrication. The measured friction forces were plotted against the incremental normal pressure and the friction coefficients were calculated. The results comparison showed clearly how employing multifunctional surfaces can reduce friction forces up to 50% at high normal loads compared to regularly ground or turned surfaces. Friction coefficients approximately equal to 0.12 were found for classically machined surfaces, whereas the values were 0.06 for multifunctional ones. All the specimens were characterized before and after testing. Wear occurrence was not detected on the tested surfaces except on the mirror-polished one which underwent all the experiments.

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Manufacture of functional surfaces through combined application of tool manufacturing processes and Robot Assisted Polishing

Cited by 25 publications

References 6 publications

The Influence of Tool Texture on Friction and Lubrication in Strip Reduction Testing

The Influence of Tool Texture on Friction and Lubrication in Strip Reduction Testing

The Influence of Tool Texture on Friction and Lubrication in Strip Reduction Testing

Testing of Newly Developed Functional Surfaces Under Pure Sliding Conditions

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