Manufacturing of structured surfaces via grinding

表面结构用于延长技术部件的使用寿命。表面结构，也称为功能表面，为冷却润滑剂提供了额外的空间，并有利于在低滑动速度下在润滑膜中产生压力。因此，减少了技术部件的摩擦，从而减少了磨损。如今，这种结构的制造通常是利用光刻、蚀刻、激光技术和高精度加工完成的。在这个合作项目中，使用具有特定形貌的特殊砂轮的传统磨削将应用于制造结构化表面，目前为止这方面的研究还很少。磨削将允许更快地生产多种材料的结构化表面，以提高技术部件所用材料的效率和可持续性。除了确定刀具的几何形状外，了解和控制加工过程的运动学对于制造确定性结构也是至关重要的。这将通过推导指定所建议的磨削过程的运动学的解析方程来实现。在这个合作项目中，将开发和研究两种不同类型的特种砂轮和运动学。德国研究小组将专注于用于平面磨削的具有明确磨粒图案的砂轮，而巴西研究小组将专注于应用圆柱面插入磨削工艺的砂轮结合剂的特殊处理。通过应用平面和外圆磨削，将考虑与滑动部件相关的所有几何形状。基于指定各自运动学的解析方程，每个研究小组将开发一种仿真工具。符合巴西集团所需结构的所需砂轮图案将使用图案生成和绘图软件进行模拟，该软件以前由巴西研究所开发，并将在拟议的项目期间进行增强。德国研究小组将开发一种模拟工具，能够识别和可视化所需的表面结构所需的颗粒图案，反之亦然。将对两组制造的结构化表面进行光学映射，并对其摩擦学性能进行评估。通过比较各种方法的可能性和局限性，将实现对结构化表面磨削能力的全面了解。不受限制地交换研究成果将导致在个别项目中不可能取得的成果，并将加强这一两国研究小组的关系。

Surface structures are used to extend technical components life. Surface structures, also called functional surfaces, provide additional space for cooling lubricant and favour the generation of pressure in the lubrication film at low sliding speeds. As a consequence, friction in technical components is decreased, resulting in reduced wear. The manufacturing of such structures is nowadays generally done applying lithography, etching, laser techniques and high-precision machining. In this collaborative project, conventional grinding using special grinding wheels with defined topographies will be applied to manufacture structured surfaces, which is only marginally researched so far. Grinding will allow a much faster production of structured surfaces in several kinds of material to improve efficiency and sustainability of materials used in technical components. Besides the defined topographies of the tools, it is essential to know and control the kinematics of the process to be able to manufacture deterministic structures. This will be achieved by deriving analytical equations that specify the kinematics of the proposed grinding process. In this collaborative project, two different kinds of special grinding wheels and kinematics will be developed and researched. The German research group will focus on grinding wheels with defined grain patterns for surface grinding, whereas the Brazilian research group will focus on special conditioning of the bond of grinding wheels applying a cylindrical plunge grinding process. By applying surface and cylindrical grinding, all geometries relevant for sliding components will be considered. Based on the analytical equations specifying the respective kinematics, each research group will develop a simulation tool. The required grinding wheel patterns accordant to desired structures of the Brazilian Group will be simulated using a pattern generation and mapping software, previously developed at the Brazilian Institute and to be enhanced during the proposed project. The German Research group will develop a simulation tool that is able to identify and visualize needed grain patterns for desired surface structures and vice versa. The manufactured structured surfaces from both groups will be optically mapped and their tribological performance will be evaluated. By comparing the possibilities and limitations of the respective approaches, a comprehensive knowledge of the capabilities of grinding structured surfaces will be achieved. The unrestricted exchange of the research results will lead to results impossible to achieve in individual projects and will strengthen the relationship of this binational research group.