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Efficient Machining of Microdimples For Friction Reduction
Efficient Machining of Microdimples For Friction Reduction
Denkena
e-mail: denkena@ifw.uni-hannover.de Efficient Machining
J. Köhler
e-mail: koehler@ifw.uni-hannover.de of Microdimples for
J. Kästner
e-mail: kaestner@ifw.uni-hannover.de
Friction Reduction
T. Göttsching1 In order to improve the tribological properties of thermomechanically highly stressed
e-mail: goettsching@ifw.uni-hannover.de surfaces such as cylinder liners, microdimples are produced by fly-cutting kinematics
along the functional surface. The structures are used to hold back lubricant but also to
Institute of Production Engineering increase the hydrodynamic pressure, which is built up between the sliding friction part-
and Machine Tools (IFW), ners. For that, machining strategies for the pattern generation in cylindrical components
Leibniz Universität Hannover, Germany are developed as well as a mathematical model of the microdimple arrangement and dis-
tribution. The tribological performance of the machined microdimples is analyzed by
means of ring-on-disk experiments. At low sliding speeds the friction coefficient can be
F. Dinkelacker decreased clearly by microdimples. This indicates the potential for low-speed or recipro-
e-mail: dinkelacker@itv.uni-hannover.de cating tribosystems like cylinder liners. This potential is quantified by motor driven
experiments and the comparison between structured and nonstructured cylinder liners. A
H. Ulmer honed (fine) liner with additional microdimples along the interstice area shows friction
e-mail: ulmer@itv.uni-hannover.de
losses up to 19% compared to standard honed nonstructured cylinder liner.
[DOI: 10.1115/1.4023757]
Institute of Technical Combustion (ITV),
Keywords: micromachining, friction reduction, cylinder liner
Leibniz Universität Hannover, Germany
1
Corresponding author.
Contributed by the Manufacturing Engineering Division of ASME for publication
in the JOURNAL OF MICRO AND NANO-MANUFACTURING. Manuscript received October 4,
2012; final manuscript received January 22, 2013; published online March 25, 2013. Fig. 1 Principle of hydrodynamic pressure build up by geo-
Assoc. Editor: Stefan Dimov. metrically defined microdimples
By the application of two different tool holder specifications, By the axial and the tangential dimple distance the number of
one parallel and one orthogonal to the machine spindle, axially microdimples on a quadrangular area DMT, with the axial edge
parallel and orthogonal process strategies are practicable. Thus, length x and the tangential edge length y, can be calculated
the outer and the inner diameter as well as the face surfaces of according to Eq. (3).
cylindrical components can be machined. By the axially parallel
strategies the outer and inner diameter surfaces are machinable x ky
where the microdimples are aligned in peripheral direction. By DMT ¼ (3)
fax U
the orthogonal strategies, in contrast, axially aligned microdim-
ples are machinable on the outer diameter surfaces. Furthermore,
the face machining with the radial and tangential alignment of the Not only the distance between two dimples but also their
microdimples is possible. arrangement to each other is relevant for the tribological behav-
ior. Within this work the parallel offset utan was defined to
Microdimple Arrangement and Distribution describe the offset of two microdimples lying upon another in
axial component direction (see Fig. 3 right). The diameter of the
In the following the impact of the machining strategy and the component and the milling tool do not have any impact on the
relevant machining parameters on the dimple distribution and parallel offset. The process parameter used to control the parallel
arrangement are analyzed. In this context, the investigations are offset is the revolution ratio kn. The interrelationship between
focused on the inner diameter machining. In Fig. 3 the relevant the revolution ratio and the resulting microdimple arrangement
parameters for the dimple arrangement are visualized. The rele- is visualized in Fig. 4, which shows the calculated parallel off-
vant process parameters to control the microdimple arrangement sets and topography plots of the machined surfaces. The diagram
are the feed fax in the axial direction of the component and the rev- on the left indicates the development of the parallel offset over a
olution ratio kn between milling tool and component. By the axial revolution ratio kn ¼ 10 to 16. In the diagram on the right the
feed fax the axial distance sax between two dimples is directly con- revolution ratio is extracted for kn ¼ 10 to 11.5. With an integer
trolled. The tangential distance stan between two microdimples in revolution ratio no offset (utan ¼ 0 deg) of the microdimples
peripheral component direction can be calculated by the compo- results, which leads to their arrangement exactly aligned. At a
nents perimeter Ucomponent and the tangential indexing ttan accord- half-integral revolution ratio the microdimples are arranged with
ing to Eq. (1). a parallel offset of exactly half of their tangential distance (50%
Ucomponent offset)
stan ¼ (1) Between an integer and a half-integral revolution ratio the
ttan
microdimples exhibit an offset to the left (negative prefix),
whereas between a half-integral and an integer revolution ratio the
The tangential indexing is calculated by Eq. (2): microdimples exhibit an offset to the right (positive prefix). By
the knowledge of these interrelations a defined offset in axial
360 deg direction of the component can be calculated and realized in a
ttan ¼ (2)
k simple way. In Fig. 4 the development of the tangential indexing
ttan is plotted against the revolution ratio as well. The tangential the described effect becomes more and more insignificant. In the
indexing decreases over the revolution ratio on a diminishing direction of very small revolution ratios the compression ratio Gc
scale due to the fact that the number of microdimples over the takes values with a negative prefix below a given point. Since the
perimeter increases with the revolution ratio. revolution ratio kv comprises the diameter of the component and
the milling tool, the speed ratio between component and milling
tool has to be taken into account. When the speed ratio is one, the
Microdimple Geometry and Process Limits compression ratio is zero. Then the cutting edge merely rolls of
By the process strategy and the process parameters the micro- the components surface and deforms it. This is demonstrated by
dimple geometry can be controlled to a certain extent as well. the triangular imprint of the cutting edge on the photomicrograph
Depending on whether the microdimples are machined by up- or in Fig. 6, middle.
downmilling the resulting trajectory of the engaging tool tip is Regarding the tool radius (rtool ¼ 10.15 mm) and the component
variable distorted. In upmilling the microdimples are stretched, radius (rcomponent ¼ 41 mm) this happens at a rotation ratio of
whereas in downmilling they are compressed. For the characteri- kn ¼ 4. With a further decrease of the rotation ratio the cutting
zation of this distortion the process characteristic stretching ratio direction reverses (negative cutting direction), where the cutting
Gs according to Eq. (4) and compression ratio Gc according to edge then merely plows through the material with its flank face in
Eq. (5) were defined. front (Fig. 6, right). Compared to the same speed ratio in positive
cutting direction the machined dimples exhibit high burr forma-
ld;ideal tion (Fig. 6, right). Recapitulatory, the machining at speed ratios
Gs ¼ (4)
ld;stretched 1 should be avoided due to the high tool tip stresses and the
poor dimple quality.
ld;ideal
Gc ¼ (5) As a further process limitation the effective clearance angle aeff
ld;compressed has to be considered during the process design. Especially the
upmilling with low speed ratios can result in very small effective
Here, ld,ideal is the length of the dimple whose trajectory is not dis- clearance angles aeff and, consequently, in a critical contact
torted (no component rotation) and ld,stretched/compressed is the between the tool flank face and the component. During the investi-
length of the dimple machined with a distorted trajectory. In the gations the revolution ratio was decreased to a minimum of
diagram in Fig. 5 the calculated stretching ratio (blue line) and kn ¼ 10 applying a tool with a clearance angle of a ¼ 7 deg. Here,
the calculated compression ratio (red line) are plotted against the the effective clearance angle was determined to aeff ¼ 4 deg so
revolution ratio for up- and downmilling. Furthermore, the meas- that no critical contact conditions were observed.
ured values gained from the experiments and photomicrographs of
the machined dimples are contrasted.
The calculated data are in correlation with the measured
ones. It becomes evident that in upmilling the tool engagement Tribological Performance of Machined Microdimples
zone is stretched, whereas in downmilling it is compressed. So, Within the investigations the tribological performance of the
the stretching and compression ratio are symmetric to G ¼ 1 (no machined surfaces with geometrically defined microdimples was
stretching/compression). With increasing revolution ratio the evaluated by a ring-on-disk setup on a Wazau TRM5000 tribome-
stretching/compression ratio converges to G ¼ 1. Consequently, ter (Fig. 7).
The experimental analysis of microstructured and nonstructured the interstice area (top dead center). The other is microstructured
cylinder liners was carried out on a heavy duty diesel single cylin- at the hydrodynamic area. Due to the reduced surface roughness,
der research engine at the Institute of Technical Combustion of the honed (fine) cylinder liner achieves, compared to the honed
the Leibniz University of Hanover. The determination of the fric- (standard) liner, less friction losses in most of the engine operating
tion reduce was carried out with the “indication method” where points (up to –11%). The honed (fine) liner with additional micro-
the FMEP is determined by the difference of indicated mean dimples along the interstice area shows the least friction losses
effective pressure and the break mean effective pressure. Figure (up to –19%) in consequence of a higher oil capture capability.
11 shows the friction effects during a 7 h test cycle of a honed The cylinder liner with the microstructured hydrodynamic area
(standard), a honed (fine) and of two microstructured cylinder lin- generates increased friction losses at engine speeds above
ers. One of those cylinder liners is equipped with microdimples at 1600 rpm. This behavior can be explained by an increased stress