| LIN Xiaohui,SUN Yuqi,SUN Guoliang,XU Jiaming.Preparation Technology of Embossed Micro-pits Array of 6061 Aluminium Alloy[J],53(23):180-189 |
| Preparation Technology of Embossed Micro-pits Array of 6061 Aluminium Alloy |
| Received:November 23, 2023 Revised:May 31, 2024 |
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| DOI：10.16490/j.cnki.issn.1001-3660.2024.23.016 |
| KeyWord:embossing micro-pits force control 6061 aluminium alloy array friction performance |
| Author | Institution |
| LIN Xiaohui |
School of Mechanical and Automotive Engineering, Xiamen University of Technology, Fujian Xiamen , China;Xiamen Key Laboratory of Robot Systems and Digital Manufacturing, Fujian Xiamen , China |
| SUN Yuqi |
School of Mechanical and Automotive Engineering, Xiamen University of Technology, Fujian Xiamen , China |
| SUN Guoliang |
School of Mechanical and Automotive Engineering, Xiamen University of Technology, Fujian Xiamen , China |
| XU Jiaming |
School of Mechanical and Automotive Engineering, Xiamen University of Technology, Fujian Xiamen , China |
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| Abstract: |
| The work aims to enhance the wear resistance of 6061 aluminum alloy and prolong its service life. The mechanical embossing technique was proposed for micro-pits array fabrication assisted by industrial robot. The cylindrical micro-pits array of 6061 aluminium alloy was embossed by impact effect with carbide tip oscillating in its axial direction at certain frequency. The electromagnetic embossing fabrication system was designed including voice motor, motion control card, signal amplifier, force sensor and industrial robot. The carbide tip was driven by voice motor and the path programming of embossing tracks were controlled by industrial robot. The embossing forces were collected by force sensor and analyzed during the embossing process. In order to improve the quality of micro-pits array, the iterative learning control system of embossing force was designed and the expected output forces were rapidly and accurately responded. Therefore, the embossing force control system could ensure the accurate and stable embossing force and controllable depths of micro-pits. The embossed micro-pits experiment of 6061 aluminium alloy was carried out and embossing force was chosen as key a parameter. Two types of arrays, rectangle and annular, were embossed on the 6061 aluminium alloy specimens. The effect of embossing force on topography of micro-pits was investigated and the consistency of micro-pits array was evaluated. Furthermore, the friction performance of micro-pits array was experimentally studied with a pin-disc-type apparatus and the effect of area density and depth on friction coefficient was investigated. The experimental results showed that the embossing force had great effect on the surface topography and depth of micro-pits. Large embossing force led to bulge and extra marks, while small embossing force caused little deformation. Hence, it was found that intact surface topographies were obtained when 25-35 N embossing force was adopted. The depths of micro-pits were positively associated with embossing force and the effective depths of micro-pits were 50-85 μm. The deviations of interval of micro-pits were mainly caused by positional accuracy of industrial robot. The deviations of depths and diameters of micro-pits were 3% and 2%, respectively, indicating that the micro-pits array had a good consistency. The friction coefficients of specimens with micro-pits array with different area density and depth of micro-pits were all less than those of as-received 6061 aluminum alloy specimens. The friction coefficients decreased with increasing of area density, however, the large area density of micro-pits led to bulge around the embossed micro-pits and the values of surface roughness increased. Thus, the friction coefficients turned to increase when area density reached 14%. The depth of micro-pits had little effect on the friction coefficients compared to area density. The embossing micro-pits were conductive to lubricating oil storage and reduction of friction in sliding contacts, the maximum sectional area of wear marks could be reduced by 63.4%. Based on this, the embossing micro-pits array on 6061 aluminium alloy is a suitable way to enhance the wear resistance. As a result, the mechanical embossing technique is a high-efficiency green process for high-quality micro-pits array fabrication, which additionally results in an enhancement in wear resistance, thus opening up a wide range of potential applications in tribologically loaded surfaces. |
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