Fabrication of a dimple structure using a machining process on a metallic surface

Abstract

A surface texture, such as a dimple structure, can be produced through various processes like electrochemistry, electrolysis, laser and machining processes. This paper presents the fabrication of a dimple structure on an aluminium alloy 6061-T6 metallic surface using a machining process comprised of turning and milling. This fabrication was enabled with the aid of a newly-developed dynamic assisted tool for the tuning and milling processes respectively. The dynamic assisted tool that was developed was able to produce a dimple structure of various shapes and geometries in the turning process (spherical, short drop and long drop), whereas for the milling process, only a circular shape could be produced. The ranges that could be produced for the dimple structures were width of 153-999 µm, length of 964-3,261 µm; diameter of 15-30 µm; depth of 37 µm-155 µm and area ratio of 2.7-13.8%. These ranges in the size, depth, area ratio and array produced were within the ranges obtained by previous researchers to minimise friction and wear for sliding mechanical components.