Fabrication of three-dimensional sin-shaped ripples using a multi-tip diamond tool based on the force modulation approach

Journal article


Wang, Y., Fan, P., Luo, X., Geng, Y., Goel, S., Wu, W., Li, G. and Yan, Y. (2021). Fabrication of three-dimensional sin-shaped ripples using a multi-tip diamond tool based on the force modulation approach. Journal of Manufacturing Processes. 72, p. 262. https://doi.org/10.1016/j.jmapro.2021.10.032
AuthorsWang, Y., Fan, P., Luo, X., Geng, Y., Goel, S., Wu, W., Li, G. and Yan, Y.
Abstract

A novel cutting strategy of machining microstructure surface with the multi-tip diamond tool based on the force modulation approach is proposed in this paper. The multi-tip diamond tool with periodic sinusoidal microstructures was prepared by focused ion beam technique. The influence of applied cutting forces on the depths of cut and material removal states was investigated experimentally. MD simulations revealed a significant phenomenon of no material side flow when using the multi-tip diamond tool cutting on single crystal copper substrate. The movement of stacking faults, Lomer-Cottrell locks and Hirth locks jointly governed the formation mechanism of machined surface. To demonstrate the feasibility and effectiveness of this proposed cutting strategy, the fabrication of periodic sinusoidal microstructures under constant forces was successfully realized on the microsphere surface. Furthermore, three-dimensional sin-shaped ripples required variable forces controlling were achieved with high-precision surface quality. The cross-sectional topography of obtained ripples corroborated the geometry of used multi-tip diamond (MTD) tool. In particular, the processing parameters, including the time period of loading forces and cutting speeds, determine the expected wavelength of ripples and play a central role in the surface machining accuracy.

KeywordsMD simulation
Year2021
JournalJournal of Manufacturing Processes
Journal citation72, p. 262
PublisherElsevier
Digital Object Identifier (DOI)https://doi.org/10.1016/j.jmapro.2021.10.032
Web address (URL)https://doi.org/10.1016/j.jmapro.2021.10.032
Publication dates
Print28 Oct 2021
Publication process dates
Accepted19 Oct 2021
Deposited20 Oct 2021
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Nanofabrication route to achieve sustainable production of next generation defect-free graphene: analysis and characterisation
Misra, S., Katiyar, N.K., Kumar, A., Goel, S. and Biswas, K. (2021). Nanofabrication route to achieve sustainable production of next generation defect-free graphene: analysis and characterisation. Nanofabrication. 6 (1), pp. 36-43. https://doi.org/10.1515/nanofab-2020-0101
Computational prediction of electrical and thermal properties of graphene and BaTiO3 reinforced epoxy nanocomposites
Mishra, R.K., Goel, S. and Nezhad, H.Y. (2021). Computational prediction of electrical and thermal properties of graphene and BaTiO3 reinforced epoxy nanocomposites. BioMaterials and Polymers Horizons. 1 (1), pp. 1-14.
Role of Thermal Spray in Combating Climate Change
Viswanathan, V., Kumar, N., Goel, G., Matthews, A. and Goel, S. (2021). Role of Thermal Spray in Combating Climate Change. Emergent Materials. https://doi.org/10.1007/s42247-021-00307-1
A Bibliometric Study on Biomimetic and Bioinspired Membranes for Water Filtration
Goel, G., Hélix-Nielsen, C., Upadhyaya, H. and Goel, S. (2021). A Bibliometric Study on Biomimetic and Bioinspired Membranes for Water Filtration . npj Clean Water. 4. https://doi.org/10.1038/s41545-021-00131-4
High yield recovery of 2,3-butanediol from fermented broth accumulated on xylose rich sugarcane bagasse hydrolysate using aqueous two-phase extraction system
Narisetty, V., Amraoui, Y., Abdullah, A., Ahmad, E., Agrawal, D., Parameswaran, B., Pandey, A., Goel, S. and Kumar, V. (2021). High yield recovery of 2,3-butanediol from fermented broth accumulated on xylose rich sugarcane bagasse hydrolysate using aqueous two-phase extraction system. Bioresource Technology. 337, p. 125463. https://doi.org/10.1016/j.biortech.2021.125463
An analytical model to predict the depth of sub-surface damage for grinding of brittle materials
Yin, J., Bai, Q., Goel, S., Zhou, P. and Zhang, B. (2021). An analytical model to predict the depth of sub-surface damage for grinding of brittle materials. CIRP Journal of Manufacturing Science and Technology . 33, pp. 454-464. https://doi.org/10.1016/j.cirpj.2021.03.019
Large scale manufacturing route to metamaterial coatings using thermal spray techniques and their response to solar radiation
Faisal, N.H., Sellami, N., Venturi, F., Hussain, T., Mallick, T., Muhammad-Sukki, F., Bishop, A., Upadhyaya, H., Kumar, N. and Goel, S. (2021). Large scale manufacturing route to metamaterial coatings using thermal spray techniques and their response to solar radiation. Emergent Materials. https://doi.org/10.1007/s42247-021-00252-z
Nature inspired materials: Emerging trends and prospects
Kumar, N., Goel, G., Hawi, S. and Goel, S. (2021). Nature inspired materials: Emerging trends and prospects . NPG Asia Materials. 15 (56). https://doi.org/10.1038/s41427-021-00322-y
Emergence of machine learning in the development of high entropy alloy and their prospects in advanced engineering applications
Kumar, N., Goel, G. and Goel, S. (2021). Emergence of machine learning in the development of high entropy alloy and their prospects in advanced engineering applications. Emergent Materials. https://doi.org/10.1007/s42247-021-00249-8
Atomic scale friction studies on single crystal GaAs using AFM and molecular dynamics simulation
Fan, P., Goel, S., Luo, X. and Upadhyaya, H. (2021). Atomic scale friction studies on single crystal GaAs using AFM and molecular dynamics simulation. Nanomanufacturing and Metrology. https://doi.org/10.1007/s41871-021-00109-3
Molecular dynamics simulation of AFM tip-based hot scratching of nanocrystalline GaAs
Fan, P., Goel, S., Luo, X., Yan, Y., Geng, Y., He, Y. and Wang, Y. (2021). Molecular dynamics simulation of AFM tip-based hot scratching of nanocrystalline GaAs. Materials Science in Semiconductor Processing. 130, p. 105832. https://doi.org/10.1016/j.mssp.2021.105832
Origins of ductile plasticity in a polycrystalline gallium arsenide during scratching: MD simulation study
Fan, P., Goel, S., Luo, X., Yan, Y., Geng, Y. and He, Y. (2021). Origins of ductile plasticity in a polycrystalline gallium arsenide during scratching: MD simulation study. Applied Surface Science. 552, p. 149489. https://doi.org/10.1016/j.apsusc.2021.149489
In-depth microscopic characterisation of the weld faying interface revealing stress-induced metallurgical transformations during friction stir spot welding
Zlatanovi, D. L., Balos, S., Bergmann, J. P., Rasche, S., Zavašnik, J., Panchal, V., Sidjanin, L. and Goel, S. (2021). In-depth microscopic characterisation of the weld faying interface revealing stress-induced metallurgical transformations during friction stir spot welding. International Journal of Machine Tools and Manufacture. 164, p. 103716.
Novel hybrid method to additively manufacture denser graphite structures using Binder Jetting.
Popov, V., Fleisher, A., Muller-Kamskii, G., Shishkin, A., Katz-Demyanetz, A., Travitzky, N. and Goel, S. (2021). Novel hybrid method to additively manufacture denser graphite structures using Binder Jetting. Scientific Reports. 11 (1), p. 2438. https://doi.org/10.1038/s41598-021-81861-w
Using circular economy principles to recycle materials in guiding the design of a wet scrubber-reactor for indoor air disinfection from coronavirus and other pathogens.
Shishkin, A., Goel, G., Baronins, J., Ozolins, J., Hoskins, C. and Goel, S. (2021). Using circular economy principles to recycle materials in guiding the design of a wet scrubber-reactor for indoor air disinfection from coronavirus and other pathogens. Environmental technology & innovation. 22, p. 101429. https://doi.org/10.1016/j.eti.2021.101429
Bactericidal surfaces: An emerging 21st-century ultra-precision manufacturing and materials puzzle
Larrañaga-Altuna, M., Zabala, A., Llavori, I., Pearce, O., Nguyen, D., Caro, J., Mescheder, Holger, Endrino, J., Goel, G., Ayre, W., Seenivasagam, R., Tripathy, D., Armstrong, Joe and Goel, S. (2021). Bactericidal surfaces: An emerging 21st-century ultra-precision manufacturing and materials puzzle. Applied Physics Reviews. 8 (2), p. 021303. https://doi.org/10.1063/5.0028844
The importance of wavelength for tight temperature control during μ-laser-assisted machining
Dennis, Ashley, Goel, S., Al-Sayegh, Rajab and O’Neill, William (2020). The importance of wavelength for tight temperature control during μ-laser-assisted machining. Journal of Micromanufacturing. 4 (1), pp. 93-98. https://doi.org/10.1177/2516598420917866
An atomistic investigation on the wear of diamond during atomic force microscope tip-based nanomachining of Gallium Arsenide
Fan, P., Goel, S., Luo, X., Yan, Y., Geng, Y. and Wang, Y. (2020). An atomistic investigation on the wear of diamond during atomic force microscope tip-based nanomachining of Gallium Arsenide. Computational Materials Science. 187, p. 110115. https://doi.org/10.1016/j.commatsci.2020.110115
New insights into the methods for predicting ground surface roughness in the age of digitalisation
Yuhang, P., Ping, Z., Ying, Y., Anupam, A., Yonghao, W., Dongming, G. and Goel, S. (2020). New insights into the methods for predicting ground surface roughness in the age of digitalisation. Precision Engineering. 67, pp. 393-418. https://doi.org/10.1016/j.precisioneng.2020.11.001
Horizons of modern molecular dynamics simulation in digitalised solid freeform fabrication with advanced materials
Goel, S., Knaggs, M., Goel, G., Zhou, X. W., Upadhyaya, H.M., Thakur, V. F., Kumar, V., Bizarri, G., Tiwari, A., Murphy, A., Stukowskii, A. and Matthewsj, A. (2020). Horizons of modern molecular dynamics simulation in digitalised solid freeform fabrication with advanced materials. Materials Today Chemistry. 18, p. 100356. https://doi.org/10.1016/j.mtchem.2020.100356
Surface Defect incorporated Diamond Machining of Silicon
Khatri, N., Barkachary, B.M., Muneeswaran, B/, Al-Sayegh, R., Luo, X. and Goel, S. (2020). Surface Defect incorporated Diamond Machining of Silicon. International Journal of Extreme Manufacturing. 2 (4). https://doi.org/10.1088/2631-7990/abab4a
Distribution of shallow NV centers in diamond revealed by photoluminescence spectroscopy and nanomachining
Jadidi, M.F., Ozer, H.O., Goel, S, Kilpatrick, J.I., McEvoy, N., McCloskey, D., Donegan, J.F. and Cross, G.L.W. (2020). Distribution of shallow NV centers in diamond revealed by photoluminescence spectroscopy and nanomachining. Carbon. 167, pp. 114-121. https://doi.org/10.1016/j.carbon.2020.04.086
Elastic recovery of monocrystalline silicon during ultra-fine rotational grinding
Huang, N., Yan, Y., Zhou, P., Kang, R., Guo, D. and Goel, S. (2020). Elastic recovery of monocrystalline silicon during ultra-fine rotational grinding. Precision Engineering. 65, pp. 64-71. https://doi.org/10.1016/j.precisioneng.2020.05.004
Resilient and Agile Engineering Solutions to Address Societal Challenges like Coronavirus Pandemic
Goel, S., Hawi, S., Goel, G., Thakur, V.K., Pearce, O., Hoskins, C., Hussain, T., Agrawal, A., Upadhyaya, H., Cross, G. and Barber, A. (2020). Resilient and Agile Engineering Solutions to Address Societal Challenges like Coronavirus Pandemic. Materials Today Chemistry. https://doi.org/10.1016/j.mtchem.2020.100300
The Critical Raw Materials in Cutting Tools for Machining Applications: A Review
Goel, S. (2020). The Critical Raw Materials in Cutting Tools for Machining Applications: A Review. Materials . 13 (1377). https://doi.org/10.3390/ma13061377
An experimental study on lap joining of multiple sheets of aluminium alloy (AA 5754) using friction stir spot welding
Goel, S., Zlatanovic DL and Balos S (2020). An experimental study on lap joining of multiple sheets of aluminium alloy (AA 5754) using friction stir spot welding. International Journal of Advanced Manufacturing Technology. 107, pp. 3093-3107. https://doi.org/10.1007/s00170-020-05214-z
Towards an improved understanding of plasticity, friction and wear mechanisms in precipitate containing AZ91 Mg alloy
Kumar D, Goel, S., Gosvami N and Jain J (2020). Towards an improved understanding of plasticity, friction and wear mechanisms in precipitate containing AZ91 Mg alloy. Materialia. 10, p. 100640. https://doi.org/10.1016/j.mtla.2020.100640
Functional evaluation and testing of a newly developed Teleost’s Fish Otolith derived biocomposite coating for healthcare
Goel, S, Montanez, N. D., Carreno, H., Escobar, P., Estupinan, H. A., Pena, D. Y. and Endrino, J. L. (2020). Functional evaluation and testing of a newly developed Teleost’s Fish Otolith derived biocomposite coating for healthcare. Scientific Reports. 10 (1), pp. 1-16. https://doi.org/10.1038/s41598-019-57128-w
Fused deposition modeling-based additive manufacturing (3D printing): techniques for polymer material systems
Daminabo, S. C., Goel, S, Grammatikos, S. A., Nezhad, H. Y. and Thakur, V. K. (2020). Fused deposition modeling-based additive manufacturing (3D printing): techniques for polymer material systems. Materials Today Chemistry. 16, p. 100248. https://doi.org/10.1016/j.mtchem.2020.100248
On the Use of the Theory of Critical Distances with Mesh Control for Fretting Fatigue Lifetime Assessment
Zabala, A., Infante-Garcia, Giner, E., Goel, S., Endrino, J.L. and Llavori, I. (2020). On the Use of the Theory of Critical Distances with Mesh Control for Fretting Fatigue Lifetime Assessment . Tribology International . 142, p. 105985. https://doi.org/https://doi.org/10.1016/j.triboint.2019.105985
Benchmarking of several material constitutive models for tribology, wear, and other mechanical deformation simulations of Ti6Al4V
Liu C, Goel S, Llavori I, Stolf P, Giusca CL, Zabala A, Kohlscheen J, Paiva JM, Endrino JL and Veldhuis SC Fox Rabinovich GS (2019). Benchmarking of several material constitutive models for tribology, wear, and other mechanical deformation simulations of Ti6Al4V. Journal of the Mechanical Behavior of Biomedical Materials. 97, pp. 126-137. https://doi.org/10.1016/j.jmbbm.2019.05.013
Fabrication of functionalised surfaces on Gum metal (Ti-30Nb) using micromachining
Hawi, S., Dickins, A., Pardal, G.R., Giusca, C., Pearce, O. and Goel, S. (2019). Fabrication of functionalised surfaces on Gum metal (Ti-30Nb) using micromachining . euspen’s 19th International Conference & Exhibition, Bilbao, ES, June 2019. Bilbao 03 - 07 Jun 2019 EUSPEN.
Suppressing the Use of Critical Raw Materials in Joining of AISI 304 Stainless Steel Using Activated Tungsten Inert Gas Welding
Balos, S., Dramicanin, M., Janjatovic, P., Zabunov, I., Pilic, B., Goel, S. and Szutkowska, M. (2019). Suppressing the Use of Critical Raw Materials in Joining of AISI 304 Stainless Steel Using Activated Tungsten Inert Gas Welding. Metals. 9 (11), p. 1187. https://doi.org/10.3390/met9111187
The role of high-pressure coolant in the wear characteristics of WC-Co tools during the cutting of Ti–6Al–4V
Stolf, P., Paiva, J.M., Ahmed, Y.S., Endrina, J.L., Goel, S. and Veldhuis, S.C. (2019). The role of high-pressure coolant in the wear characteristics of WC-Co tools during the cutting of Ti–6Al–4V. Wear. 440-441, p. 203090. https://doi.org/10.1016/j.wear.2019.203090
Molecular dynamics simulation of the elliptical vibration assisted machining (EVAM) of pure iron
Goel S, Martinez FD, Chavoshi SZ, Khatri N and Giusca C (2018). Molecular dynamics simulation of the elliptical vibration assisted machining (EVAM) of pure iron. Journal of Micromanufacturing. 1 (1), pp. 6-19. https://doi.org/10.1177/2516598418765359
The possibility of performing FEA analysis of a contact loading process fed by the MD simulation data
Goel S, Iñigo Llavori AZ, Giusca C, Veldhuis SC and Endrino JL (2018). The possibility of performing FEA analysis of a contact loading process fed by the MD simulation data. International Journal of Machine Tools and Manufacture. 134, pp. 79-80. https://doi.org/10.1016/j.ijmachtools.2018.07.003
Incipient plasticity in tungsten during nanoindentation: Dependence on surface roughness, probe radius and crystal orientation
Beake B and Goel, S. (2018). Incipient plasticity in tungsten during nanoindentation: Dependence on surface roughness, probe radius and crystal orientation. International Journal of Refractory Metals and Hard Materials. 75, pp. 63-69. https://doi.org/https://doi.org/10.1016/j.ijrmhm.2018.03.020
Designing nanoindentation simulation studies by appropriate indenter choices: Case study on single crystal tungsten
Goel, S., Cross, G., Stukowski, A., Gamsjager, E., Beake, B. and Agrawal, A. (2018). Designing nanoindentation simulation studies by appropriate indenter choices: Case study on single crystal tungsten. Computational Materials Science. 152, pp. 196-210. https://doi.org/https://doi.org/10.1016/j.commatsci.2018.04.044
Current trends and future of sequential micro-machining processes on a single machine tool
Chavoshi, S.Z., Goel, S. and Morantz, P. (2017). Current trends and future of sequential micro-machining processes on a single machine tool. Materials & Design. 127, pp. 37-53. https://doi.org/10.1016/j.matdes.2017.04.057
Cyclic nanoindentation and nano-impact fatigue mechanisms of functionally graded TiN/TiNi film
Faisal NH, Prathuru AK, Goel S, Ahmed R, Droubi MG, Beake BD and Fu YQ (2017). Cyclic nanoindentation and nano-impact fatigue mechanisms of functionally graded TiN/TiNi film. Shape Memory and Superelasticity. 3, pp. 149-167. https://doi.org/10.1007/s40830-017-0099-y
Addressing the discrepancy of finding equilibrium melting point of silicon using MD simulations
Chavoshi SZ, Xu S and Goel S (2017). Addressing the discrepancy of finding equilibrium melting point of silicon using MD simulations. Proceedings of the Royal Society A: Mathematical, Physical and Engineering Sciences. https://doi.org/10.1098/rspa.2017.0084
Influence of temperature on the anisotropic cutting behaviour of single crystal silicon: A molecular dynamics simulation investigation
Chavoshi, S.Z., Goel, S. and Luo, X. (2016). Influence of temperature on the anisotropic cutting behaviour of single crystal silicon: A molecular dynamics simulation investigation. Journal of Manufacturing Processes. 23, pp. 201-210. https://doi.org/10.1016/j.jmapro.2016.06.009
Advances in the surface defect machining (SDM) of hard steels
Rashid, W.B. and Goel, S. (2016). Advances in the surface defect machining (SDM) of hard steels. Journal of Manufacturing Processes. 23, pp. 37-46. https://doi.org/10.1016/j.jmapro.2016.05.007
Influence of microstructure on the cutting behaviour of silicon
Goel, S., Kovalchenko, A., Stukowski, A. and Cross, G. (2016). Influence of microstructure on the cutting behaviour of silicon. Acta Materialia. 105, pp. 464-478. https://doi.org/10.1016/j.actamat.2015.11.046