Skip to main content
SpringerLink
Log in

Generation mechanism of surface micro-texture in axial ultrasonic vibration-assisted milling (AUVAM)

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Although axial ultrasonic vibration-assisted milling (AUVAM) is promising for rapid and economical fabrication of 3D micro-texture on various surfaces, it has been a challenge to obtain micro-texture with small feature size and large height simultaneously. The mechanism and major influence factors for the formation of micro-texture by this method were explored in this study. It was found that the generation of micro-texture was mainly caused by cutting and extrusion from the flank face of the milling tool under ultrasonic vibration. Therefore, a novel 3D tool model that considered the relief angle, end cutting edge angle and the blade profile was established in simulation analysis. The good agreement between simulation and experimental results demonstrated that the influence of the flank face on the micro-texture was mainly attributed to the relief angle of the milling tool. It was the first time to report that both the height and the profile shape of the micro-texture unit were affected by the overlap and extrusion between the flank surface and the micro-texture. But this influence diminished with the increase of spindle speed. 3D sinusoid-shaped micro-texture with minimum width of 20 μm and height of 2 μm (fully reproduced the ultrasonic amplitude) was realized with the relief angle of 40° and spindle speed of 4000 rpm. Other typical textures of weave, shell, scale and corrugation were also presented to show the effective regulation of texture patterns in AUVAM. This work provides both theoretical and practical basis for such a low-cost, efficient and controllable 3D micro-texture preparation method.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18

Similar content being viewed by others

References

  1. Jiang Y, Shen H, Pu T, Zheng C, Tang Q, Gao K, Wu J, Rui C, Li Y, Liu Y (2017) High efficiency multi-crystalline silicon solar cell with inverted pyramid nanostructure. Sol Energy 142:91–96. https://doi.org/10.1016/j.solener.2016.12.007

    Article  Google Scholar 

  2. Li L, Yi AY (2010) Development of a 3D artificial compound eye. Opt Express 18:18125–18137. https://doi.org/10.1364/oe.18.018125

    Article  Google Scholar 

  3. Sun J, Luo X, Chang W, Ritchie JM, Chien J, Lee A (2012) Fabrication of periodic nanostructures by single-point diamond turning with focused ion beam built tool tips. J Micromech Microeng. https://doi.org/10.1088/0960-1317/22/11/115014

    Article  Google Scholar 

  4. Jahed Z, Molladavoodi S, Seo BB, Gorbet M, Tsui TY, Mofrad MR (2014) Cell responses to metallic nanostructure arrays with complex geometries. Biomaterials 35:9363–9371. https://doi.org/10.1016/j.biomaterials.2014.07.022

    Article  Google Scholar 

  5. Jeon H, Simon CG JR, Kim G (2014) A mini-review: Cell response to microscale, nanoscale, and hierarchical patterning of surface structure. J Biomed Mater Res B Appl Biomater 102:1580–1594 https://doi.org/10.1002/jbm.b.33158

  6. Zhang J, Tian W, Chen J, Yu J, Zhang J, Chen J (2019) The application of polyetheretherketone (PEEK) implants in cranioplasty. Brain Res Bull 153:143–149. https://doi.org/10.1016/j.brainresbull.2019.08.010

    Article  Google Scholar 

  7. Zhao W, Wang L, Xue Q (2010) Design and fabrication of nanopillar patterned au textures for improving nanotribological performance. ACS Appl Mater Interfaces 2:788–794. https://doi.org/10.1021/am900788t

    Article  Google Scholar 

  8. Zhang S, Zhou Y, Zhang H, Xiong Z, To S (2019) Advances in ultra-precision machining of micro-structured functional surfaces and their typical applications. Int J Mach Tools Manuf 142:16–41. https://doi.org/10.1016/j.ijmachtools.2019.04.009

    Article  Google Scholar 

  9. Hosseinabadi HN, Sajjady SA, Amini S (2018) Creating micro textured surfaces for the improvement of surface wettability through ultrasonic vibration assisted turning. Int J Adv Manuf Technol 96:2825–2839. https://doi.org/10.1007/s00170-018-1580-2

    Article  Google Scholar 

  10. Chowdhury H, Loganathan B, Wang Y, Mustary I, Alam F (2016) A Study of Dimple Characteristics on Golf Ball Drag. Procedia Eng 147:87–91. https://doi.org/10.1016/j.proeng.2016.06.194

    Article  Google Scholar 

  11. Chen X, Zhai W, Dong S, Zheng K, Xu R, Wang J, Liu X, Lu W (2020) Investigations on torsional fretting wear properties of CuAlNi processed by ultrasonic vibration-assisted milling. Tribol Int. https://doi.org/10.1016/j.triboint.2020.106238

    Article  Google Scholar 

  12. Hussain SQ, Ahn S, Park H, Kwon G, Raja J, Lee Y, Balaji N, Kim H, Le AHT, Yi J (2013) Light trapping scheme of ICP-RIE glass texturing by SF6/Ar plasma for high haze ratio. Vacuum 94:87–91. https://doi.org/10.1016/j.vacuum.2013.01.026

    Article  Google Scholar 

  13. Liu X, Li Y (2011) Analysis of LIGA-Ni Microstructure. AEMT, Sanya, PEOPLES R CHINA 284–286:1574–1578. https://doi.org/10.4028/www.scientific.net/AMR.284-286.1574

    Article  Google Scholar 

  14. Borjali A, Monson K, Raeymaekers B (2018) Friction between a polyethylene pin and a microtextured CoCrMo disc, and its correlation to polyethylene wear, as a function of sliding velocity and contact pressure, in the context of metal-on-polyethylene prosthetic hip implants. Tribol Int 127:568–574. https://doi.org/10.1016/j.triboint.2018.07.005

    Article  Google Scholar 

  15. Koyano T, Hosokawa A, Takahashi T, Ueda T (2019) One-process surface texturing of a large area by electrochemical machining with short voltage pulses. CIRP Ann 68:181–184. https://doi.org/10.1016/j.cirp.2019.04.100

    Article  Google Scholar 

  16. Xu S, Kuriyagawa T, Shimada K, Mizutani M (2017) Recent advances in ultrasonic-assisted machining for the fabrication of micro/nano-textured surfaces. Front Mech Eng China 12:33–45. https://doi.org/10.1007/s11465-017-0422-5

    Article  Google Scholar 

  17. Liu Q, Xu J, Yu H (2020) Experimental study of tool wear and its effects on cutting process of ultrasonic-assisted milling of Ti6Al4V. Int J Adv Manuf Technol 108:2917–2928. https://doi.org/10.1007/s00170-020-05593-3

    Article  Google Scholar 

  18. Verma GC, Pandey PM, Dixit US (2018) Modeling of static machining force in axial ultrasonic-vibration assisted milling considering acoustic softening. Int J Mech Sci 136:1–16. https://doi.org/10.1016/j.ijmecsci.2017.11.048

    Article  Google Scholar 

  19. Ni C, Zhu L (2020) Investigation on machining characteristics of TC4 alloy by simultaneous application of ultrasonic vibration assisted milling (UVAM) and economical-environmental MQL technology. J Mater Process Technol. https://doi.org/10.1016/j.jmatprotec.2019.116518

    Article  Google Scholar 

  20. Chen G, Ren C, Zou Y, Qin X, Lu L, Li S (2019) Mechanism for material removal in ultrasonic vibration helical milling of Ti 6Al 4V alloy. Int J Mach Tools Manuf 138:1–13. https://doi.org/10.1016/j.ijmachtools.2018.11.001

    Article  Google Scholar 

  21. Baraheni M, Amini S (2020) Mathematical model to predict cutting force in rotary ultrasonic assisted end grinding of Si3N4 considering both ductile and brittle deformation. Measurement. https://doi.org/10.1016/j.measurement.2020.107586

    Article  Google Scholar 

  22. Amini S, Baraheni M, Khaki M (2021) Empirical study on ultrasonic assisted turn-milling. Proc. Inst. Mech. Eng. Part E: J Process Mech Eng 235:1469–1478. https://doi.org/10.1177/09544089211008714

    Article  Google Scholar 

  23. Feng Y, Hsu FC, Lu YT, Lin YF, Lin CT, Lin CF, Lu YC, Liang SY (2019) Residual stress prediction in ultrasonic vibration–assisted milling. Int J Adv Manuf Technol 104:2579–2592. https://doi.org/10.1007/s00170-019-04109-y

    Article  Google Scholar 

  24. Feng Y, Hsu FC, Lu YT, Lin YF, Lin CT, Lin CF, Lu YC, Liang SY (2020) Temperature prediction of ultrasonic vibration-assisted milling. Ultrasonics 108:106212. https://doi.org/10.1016/j.ultras.2020.106212

    Article  Google Scholar 

  25. Feng Y, Hsu FC, Lu YT, Lin YF, Lin CT, Lin CF, Lu YC, Liang SY (2020) Force prediction in ultrasonic vibration-assisted milling. Mach Sci Technol 25:307–330. https://doi.org/10.1080/10910344.2020.1815048

    Article  Google Scholar 

  26. Feng Y, Hsu FC, Lu YT, Lin YF, Lin CT, Lin CF, Lu YC, Liang SY (2020) Tool wear rate prediction in ultrasonic vibration-assisted milling. Mach Sci Technol 24:758–780. https://doi.org/10.1080/10910344.2020.1752240

    Article  Google Scholar 

  27. Feng Y, Hsu FC, Lu YT, Lin YF, Lin CT, Lin CF, Lu YC, Lu X, Liang SY (2020) Surface roughness prediction in ultrasonic vibration-assisted milling. J Adv Mech Des Syst Manuf 14:JAMDSM0063-JAMDSM0063. https://doi.org/10.1299/jamdsm.2020jamdsm0063

  28. Shen XH, Tao GC (2015) Tribological behaviors of two micro textured surfaces generated by vibrating milling under boundary lubricated sliding. Int J Adv Manuf Technol 79:1995–2002. https://doi.org/10.1007/s00170-015-6965-x

    Article  Google Scholar 

  29. Chen W, Zheng L, Huo D, Chen Y (2018) Surface texture formation by non-resonant vibration assisted micro milling. J Micromech Microeng. https://doi.org/10.1088/1361-6439/aaa06f

    Article  Google Scholar 

  30. Chen W, Zheng L, Xie W, Yang K, Huo D (2019) Modelling and experimental investigation on textured surface generation in vibration-assisted micro-milling. J Mater Process Technol 266:339–350. https://doi.org/10.1016/j.jmatprotec.2018.11.011

    Article  Google Scholar 

  31. Shen XH, Shi YL, Zhang JH, Zhang QJ, Tao GC, Bai LJ (2020) Effect of process parameters on micro-textured surface generation in feed direction vibration assisted milling. Int J Mech Sci. https://doi.org/10.1016/j.ijmecsci.2019.105267

    Article  Google Scholar 

  32. Lu H, Zhu L, Yang Z, Lu H, Yan B, Hao Y, Qin S (2021) Research on the generation mechanism and interference of surface texture in ultrasonic vibration assisted milling. Int J Mech Sci. https://doi.org/10.1016/j.ijmecsci.2021.106681

    Article  Google Scholar 

  33. Börner R, Winkler S, Junge T, Titsch C, Schubert A, Drossel WG (2018) Generation of functional surfaces by using a simulation tool for surface prediction and micro structuring of cold-working steel with ultrasonic vibration assisted face milling. J Mater Process Technol 255:749–759. https://doi.org/10.1016/j.jmatprotec.2018.01.027

    Article  Google Scholar 

  34. Zhao B, Li P, Zhao C, Wang X (2020) Fractal characterization of surface microtexture of Ti6Al4V subjected to ultrasonic vibration assisted milling. Ultrasonics. https://doi.org/10.1016/j.ultras.2019.106052

    Article  Google Scholar 

  35. Guo P, Ehmann KF (2013) An analysis of the surface generation mechanics of the elliptical vibration texturing process. Int J Mach Tools Manuf 64:85–95. https://doi.org/10.1016/j.ijmachtools.2012.08.003

    Article  Google Scholar 

  36. Liu X, Wu D, Zhang J, Hu X, Cui P (2019) Analysis of surface texturing in radial ultrasonic vibration-assisted turning. J Mater Process Technol 267:186–195. https://doi.org/10.1016/j.jmatprotec.2018.12.021

    Article  Google Scholar 

  37. Kilic ZM, Altintas Y (2016) Generalized modelling of cutting tool geometries for unified process simulation. Int J Mach Tools Manuf 104:14–25. https://doi.org/10.1016/j.ijmachtools.2016.01.007

    Article  Google Scholar 

  38. Tao G, Ma C, Bai L, Shen X, Zhang J (2016) Feed-direction ultrasonic vibration−assisted milling surface texture formation. Mater Manuf Processes 32:193–198. https://doi.org/10.1080/10426914.2016.1198029

    Article  Google Scholar 

  39. Gao H, Yue C, Liu X, Nan Y (2019) Simulation of surface topography considering cut-in impact and tool flank wear. Appl Sci. https://doi.org/10.3390/app9040732

    Article  Google Scholar 

  40. Zhu L, Ni C, Yang Z, Liu C (2019) Investigations of micro-textured surface generation mechanism and tribological properties in ultrasonic vibration-assisted milling of Ti–6Al–4V. Precis Eng 57:229–243. https://doi.org/10.1016/j.precisioneng.2019.04.010

    Article  Google Scholar 

Download references

Acknowledgements

The authors sincerely appreciate financial supports from Fundamental Research Funds for the Central Universities (19CX02020A) and the National Natural Science Foundation of China (51905546), Key Technology Research and Development Program of Shandong (2018GGX103034).

Author information

Authors and Affiliations

  1. College of Mechanical and Electrical Engineering, China University of Petroleum (East China), Qingdao, 266580, People’s Republic of China

    Zongbo Zhang, Wengang Liu, Xintong Chen, Yu Zhang, Chunling Xu, Kai Wang, Wei Wang & Xin Jiang

Authors
  1. Zongbo Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Wengang Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Xintong Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Yu Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Chunling Xu
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Kai Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Wei Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  8. Xin Jiang
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

First author contributions established theoretical model, conceived and designed experiments, analyzed the data and wrote the initial manuscript. Corresponding author contributions received editor correspondence and send in revisions. Second author contributions established theoretical model, performed the experiments; analyzed the data; contributed on the writing of the manuscript. Other co-authors contributions: all co-authors have almost contributed equally. The major work involved is as follows: performed the experiments; contributed to reagents and materials; sent the sample to the test; analyzed the data; and reviewed each paper draft.

Corresponding author

Correspondence to Zongbo Zhang.

Ethics declarations

Competing Interests

The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Supplementary Information

Below is the link to the electronic supplementary material.

Supplementary file1 (DOCX 3716 KB)

Rights and permissions

Springer Nature or its licensor holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Zhang, Z., Liu, W., Chen, X. et al. Generation mechanism of surface micro-texture in axial ultrasonic vibration-assisted milling (AUVAM). Int J Adv Manuf Technol 122, 1651–1667 (2022). https://doi.org/10.1007/s00170-022-09974-8

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-022-09974-8

Keywords

Search

Navigation