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Research Papers: Hydrodynamic Lubrication

Tribological Performance of Textured Surfaces Created by Modulation-Assisted Machining

[+] Author and Article Information
Andrew Tock

Mechanical Engineering Department,
Rochester Institute of Technology,
76 Lomb Memorial Drive,
Rochester, NY 14623
e-mail: adt2843@rit.edu

Rahul Gandhi

Department of Industrial and
Manufacturing Engineering,
Pennsylvania State University,
State College, PA 16802
e-mail: gandhirahulrajeev@gmail.com

Christopher Saldana

George W. Woodruff School of
Mechanical Engineering,
Manufacturing Research (MaRC),
Building Atlanta,
Atlanta, GA 30332-0405
e-mail: christopher.saldana@me.gatech.edu

Patricia Iglesias

Mem. ASME
Mechanical Engineering Department,
Rochester Institute of Technology,
76 Lomb Memorial Drive,
Rochester, NY 14623
e-mail: pxieme@rit.edu

Contributed by the Tribology Division of ASME for publication in the JOURNAL OF TRIBOLOGY. Manuscript received December 7, 2017; final manuscript received April 24, 2018; published online May 21, 2018. Assoc. Editor: Bart Raeymaekers.

J. Tribol 140(6), 061704 (May 21, 2018) (8 pages) Paper No: TRIB-17-1475; doi: 10.1115/1.4040149 History: Received December 07, 2017; Revised April 24, 2018

Methods for scalable surface texturing continue to receive significant attention due to the importance of microtextured surfaces toward improving friction, wear, and lubrication ability of mechanical devices. Controlled textures on surfaces act as fluid reservoirs and receptacles for debris and wear particles, reducing friction and wear of mating components. There are numerous fabrication techniques that can be used to create microsized depressions on surfaces, but each has limitations in terms of control and scalability. In the present study, modulation-assisted machining (MAM) is demonstrated as a viable approach to produce such textures, offering a potentially cost-effective approach for scalable production of these features on component surfaces. In this work, the wear behavior of several textured surfaces created by MAM was studied using a ball-on-flat reciprocating tribometer. Textured and untextured alloy 360 brass disks were mated with stainless steel AISI 440C balls under lubricated conditions and variable sliding distance. The textured surfaces exhibited noticeably reduced wear under the longer sliding distances and the tribological performance of the surfaces depended on the size of the microdimples. Wear mechanisms are elucidated from the optical microscopy, scanning electron microscopy (SEM), and energy dispersive spectroscopy (EDS) observations and the implications for using such surfaces in practice are briefly discussed.

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Figures

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Fig. 3

Average wear volume from: (a) wear track width [13] and (b) from profilometer [12]—effect of sliding distance

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Fig. 4

Profile of a wear track on CS after a sliding distance of 76 m

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Fig. 2

Images of sample: (a) #1A (constant surface speed) and (b) #1B (constant spindle speed)

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Fig. 1

(a) Machine setup for texturing surfaces and (b) schematic representation of a plunging-type texturing configuration

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Fig. 5

Wear track on: (a) CS after 38 m; (b) #1A after 38 m; (c) #1B after 38 m; (d) CS after 76 m; (e) #1A after 76 m; and (f) #1B after 76 m

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Fig. 6

Optical micrographs of steel pins after a test against: (a) CS (19 m); (b) CS (38 m); (c) CS (76 m); (d) #1A (19 m); (e) #1A (38 m), and (f) #1A (76 m). Arrows show adhered material.

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Fig. 7

Optical images and white light interferometric scans of samples: (a) and (e) #2A; (b) and (f) #2B; (c) and (g) #2C; (d) and (h) #2D

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Fig. 8

Average wear volume by image analysis [13]—effect of dimple length and depth

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Fig. 9

Optical images of wear tracks on: (a) #2A; (b) and (d) #2B; (c) and (e) #2C

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Fig. 10

SEM micrographs of wear tracks on CS after sliding distance: (a) and (c) 38 m; (b) and (d) 76 m

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Fig. 11

SEM micrographs of wear tracks on #1A after a sliding distance of 76 m

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Fig. 12

SEM micrographs and corresponding Fe, Cu, and Zn maps of steel ball after a test against CS (76 m)

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Fig. 13

SEM micrographs of wear tracks and corresponding O and Fe maps after sliding distance of 76 m on: (a) CS and (b) #1A

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