Analysis of dimple structure fabricated using turning process and subsequent reduction in friction

Research output: Contribution to journalArticle

Abstract

Dimples is an important structure in the context of surface texturing due to its role in improving the heat transfer while minimizing wear and friction on sliding mechanical components. In this study, various sizes and shapes of dimple structures were fabricated on a cylindrical surface of a hyper eutectic aluminum silicon alloy (A390) using the turning process with the aid of a dynamic-assisted tooling (DATT), which was designed and fabricated in-house. The turning process was selected based on factors such as the capability of its machining process, low cost, minimum setup time, and green working environment. The dimples’ shapes fabricated in this study were short drop, long drop, and spherical, with widths of 397–920 µm, lengths of 2420–3261 µm, depths of 64–155 µm, and area ratios of 10–15.68%. The tribology test conducted on the samples confirmed that the coefficient of friction of these dimples in a hydrodynamic regime was 0.22–0.24 relative to the smooth surface's at 0.5, which is a maximum of 56% friction reduction. No microstructural changes were observed beneath the machined surface of the dimpled area and surface roughness (Ra) in the case of both dimple and non-dimpled surfaces. Dimple fabrication using the turning process is therefore recommended to the manufacturing industry if they intend to preserve material properties within friendly working environment(s).

Original languageEnglish
JournalWear
DOIs
Publication statusAccepted/In press - 1 Jan 2018

Fingerprint

friction
Friction
friction reduction
tooling
Silicon alloys
silicon alloys
tribology
Texturing
Tribology
machining
eutectics
aluminum alloys
coefficient of friction
Eutectics
sliding
Aluminum alloys
Materials properties
Machining
surface roughness
roughness

Keywords

  • Aluminum silicon alloy (A390)
  • Coefficient of friction (COF)
  • Dimple structure
  • Material property
  • Turning process

ASJC Scopus subject areas

  • Condensed Matter Physics
  • Mechanics of Materials
  • Surfaces and Interfaces
  • Surfaces, Coatings and Films
  • Materials Chemistry

Cite this

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title = "Analysis of dimple structure fabricated using turning process and subsequent reduction in friction",
abstract = "Dimples is an important structure in the context of surface texturing due to its role in improving the heat transfer while minimizing wear and friction on sliding mechanical components. In this study, various sizes and shapes of dimple structures were fabricated on a cylindrical surface of a hyper eutectic aluminum silicon alloy (A390) using the turning process with the aid of a dynamic-assisted tooling (DATT), which was designed and fabricated in-house. The turning process was selected based on factors such as the capability of its machining process, low cost, minimum setup time, and green working environment. The dimples’ shapes fabricated in this study were short drop, long drop, and spherical, with widths of 397–920 µm, lengths of 2420–3261 µm, depths of 64–155 µm, and area ratios of 10–15.68{\%}. The tribology test conducted on the samples confirmed that the coefficient of friction of these dimples in a hydrodynamic regime was 0.22–0.24 relative to the smooth surface's at 0.5, which is a maximum of 56{\%} friction reduction. No microstructural changes were observed beneath the machined surface of the dimpled area and surface roughness (Ra) in the case of both dimple and non-dimpled surfaces. Dimple fabrication using the turning process is therefore recommended to the manufacturing industry if they intend to preserve material properties within friendly working environment(s).",
keywords = "Aluminum silicon alloy (A390), Coefficient of friction (COF), Dimple structure, Material property, Turning process",
author = "{A Ghani}, Jaharah and Dali, {M. N.A.M.} and Rahman, {H. A.} and {Che Haron}, {Che Hassan} and {Wan Mahmood}, {Wan Mohd Faizal} and {Mohammad Rasani}, {Mohammad Rasidi} and Nuawi, {Mohd. Zaki}",
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T1 - Analysis of dimple structure fabricated using turning process and subsequent reduction in friction

AU - A Ghani, Jaharah

AU - Dali, M. N.A.M.

AU - Rahman, H. A.

AU - Che Haron, Che Hassan

AU - Wan Mahmood, Wan Mohd Faizal

AU - Mohammad Rasani, Mohammad Rasidi

AU - Nuawi, Mohd. Zaki

PY - 2018/1/1

Y1 - 2018/1/1

N2 - Dimples is an important structure in the context of surface texturing due to its role in improving the heat transfer while minimizing wear and friction on sliding mechanical components. In this study, various sizes and shapes of dimple structures were fabricated on a cylindrical surface of a hyper eutectic aluminum silicon alloy (A390) using the turning process with the aid of a dynamic-assisted tooling (DATT), which was designed and fabricated in-house. The turning process was selected based on factors such as the capability of its machining process, low cost, minimum setup time, and green working environment. The dimples’ shapes fabricated in this study were short drop, long drop, and spherical, with widths of 397–920 µm, lengths of 2420–3261 µm, depths of 64–155 µm, and area ratios of 10–15.68%. The tribology test conducted on the samples confirmed that the coefficient of friction of these dimples in a hydrodynamic regime was 0.22–0.24 relative to the smooth surface's at 0.5, which is a maximum of 56% friction reduction. No microstructural changes were observed beneath the machined surface of the dimpled area and surface roughness (Ra) in the case of both dimple and non-dimpled surfaces. Dimple fabrication using the turning process is therefore recommended to the manufacturing industry if they intend to preserve material properties within friendly working environment(s).

AB - Dimples is an important structure in the context of surface texturing due to its role in improving the heat transfer while minimizing wear and friction on sliding mechanical components. In this study, various sizes and shapes of dimple structures were fabricated on a cylindrical surface of a hyper eutectic aluminum silicon alloy (A390) using the turning process with the aid of a dynamic-assisted tooling (DATT), which was designed and fabricated in-house. The turning process was selected based on factors such as the capability of its machining process, low cost, minimum setup time, and green working environment. The dimples’ shapes fabricated in this study were short drop, long drop, and spherical, with widths of 397–920 µm, lengths of 2420–3261 µm, depths of 64–155 µm, and area ratios of 10–15.68%. The tribology test conducted on the samples confirmed that the coefficient of friction of these dimples in a hydrodynamic regime was 0.22–0.24 relative to the smooth surface's at 0.5, which is a maximum of 56% friction reduction. No microstructural changes were observed beneath the machined surface of the dimpled area and surface roughness (Ra) in the case of both dimple and non-dimpled surfaces. Dimple fabrication using the turning process is therefore recommended to the manufacturing industry if they intend to preserve material properties within friendly working environment(s).

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