An analysis of the surface generation mechanics of the elliptical vibration texturing process

• Published in: International journal of machine tools & manufacture Vol. 64; pp. 85 - 95
• Main Authors: Guo, Ping, Ehmann, Kornel F.
• Format: Journal Article
• Language: English
• Published: Kidlington Elsevier Ltd 01.01.2013; Elsevier
• Subjects: Applied sciences; Computer simulation; Cross-disciplinary physics: materials science; rheology; Cutting parameters; Cutting tools; Elliptical vibration texturing; Exact sciences and technology; Machine tool kinematics; Materials science; Mathematical models; Mechanical engineering. Machine design; Micro cutting; Physics; Precision engineering, watch making; Structured surfaces; Surface generation; Surface treatments; Tertiary motion generator; Texture; Texturing; Vibration; Elliptical vibration texturing; Surface generation; Micro cutting; Machine tool kinematics; Tertiary motion generator; Structured surfaces; Cutting tools; Scale models; Surface treatments; Surface analysis; Texture; Surface states; Penetration depth; Vibration machining; Topography; Kinematics; Springback; Scaling laws; Tool design; Alveolus; Modelling; Geometrical shape; Micromachining; Experimental study; vibration assisted process; Non linear effect; Microstructure
• ISSN: 0890-6955; 1879-2170
• DOI: 10.1016/j.ijmachtools.2012.08.003

The elliptical vibration texturing process is a vibration assisted machining method for the fast generation of micro structured surfaces. It adds a higher order motion component to the cutting tool that leads to periodic changes in the cutting depth during the machining process. This results in the creation of micro-dimples on the machined surface, whose shape is a function of the tool geometry and trajectory. This paper studies the surface generation mechanics of the elliptical vibration texturing process through experimentation and modeling. A surface generation algorithm is presented for this newly developed process. The model fully describes the motion and the 3D geometry of the cutting tool including its rake face, flank face, and the cutting edge, since all these tool features influence the topography of the generated surface. Since the process takes place in the micro/meso-scale cutting regime, the model includes the minimum chip thickness and elastic recovery effects. The experimental results are shown to validate the simulation model. The simulation model is used to characterize the influences of the process parameters on the texture patterns. The effects of the tool geometry on the process, including the cutting edge radius, are also analyzed. ► An innovative process is proposed for the fast generation of structured surfaces. ► The simulation model includes the full description of the 3D tool geometry. ► The model takes into account elastic recovery and minimum chip thickness effects. ► The proposed process and model are experimentally verified. ► The effects of process parameters on the surface topography are analyzed.