Fabrication of 3D submicron to micro textured surfaces using backside patterned texturing (BPT) |
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Affiliation: | 1. SIMTech-NTU Joint Lab on Precision Engineering, School of Mechanical and Aerospace Engineering, Nanyang Technological University, Singapore;2. SIMTech-NTU Joint Lab on Precision Engineering, Singapore Institute of Manufacturing Technology, A*STAR, Singapore;1. Department of Electronic Engineering, City University of Hong Kong, 83 Tat Chee Avenue, Kowloon, Hong Kong;2. Bradley Department of Electrical and Computer Engineering, Virginia Tech, Blacksburg, VA 24061, USA;1. State Key Laboratory of Mechanical System and Vibration, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China;2. School of Material Science and Engineering, Nanchang Hangkong University, Nanchang 330034, China;3. School of Energy & School of Physical Science and Technology, Soochow University, Suzhou 215006, China |
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Abstract: | This work presents a novel fabrication method for submicron to micro size textures on flat surfaces using the backside patterned texturing (BPT). The proposed method utilizes the pre-fabricated macro-features on the backside of work material, and thereafter the front side is face turned with a single point diamond tool to generate textured surfaces. Different from existing texturing methods, BPT produces textured surfaces from submicron to micro scale without any external gadgets such as vibration assisted machining or synchronized tool-spindle motion. The miniature feature arises on the diamond turned surface due to the induced residual stresses when the specimen is unleashed from the machine. To demonstrate the efficacy of the method, a series of machining experiments were conducted to fabricate various types of freeform surface textures like water-drop freeform, cylindrical freeform surfaces, etc. The fabrication methodology of different sizes of bumps with precisely controlled surface quality is illustrated. The texture profiles comprising the deformation height from hundreds of nanometer to few micrometers with mirror surface quality were successfully fabricated on the diamond machined surface. The experimental results suggest that the pre-fabricated pattern, workpiece thickness and machining condition play a critical role to determine the final shape and geometry of generated textures. |
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Keywords: | Ultraprecision machining Micro texturing Submicron features Diamond turning Backside pattern texturing Induced stresses |
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