Lubrication Method Research Articles

An Investigation on the Performance of the Ultrasonic Atomization-Based Cutting Fluid (uACF) Spray System

Nowadays, due to limited resources and manufacturers desire to keep manufacturing costs at the lowest level, minimum quantity lubrication systems stand out. Ultrasonic atomization-based cutting fluid (uACF) spray system, which is one of the minimum quantity lubrication methods, attracts attention with its low production cost and much lower cutting fluid consumption compared to conventional cooling systems. A limited number of studies have been carried out to demonstrate the performance of this innovative, compact and environmentally friendly system under real cutting conditions. uACF system was compared with spray cooling (SPR), compressed air cooling (AIR) and dry machining (DRY) conditions using similar machining parameters. Cutting speed and feed rate were selected as machining parameters. The effect of the machining parameters on the cutting force (Fc), cutting temperature (Tc), average surface roughness (Ra) and chip shrinkage coefficient (ξ) were compared with other systems. The study concluded that the uACF system can outperform or compete with different cooling methods in all performance outputs with the right choice of cutting parameter combination. In addition, the study also revealed the effects of cutting speed and feed rate levels on performance outputs under different cooling conditions. In the light of the data obtained from the study, it is concluded that the uACF system provides a good performance under real cutting conditions with a low amount of cutting fluid consumption (0.5 ml/min) with low operating cost and has a high utilisation potential.

Investigating the efficiency of mixtures based on supercritical CO2 and lubricants by friction tests under conditions similar to the machining of Ti6Al4V

New supercritical carbon dioxide (scCO2)-based cutting fluids combining the cooling from scCO2 and lubrication from various additives are investigated in this study. Selected components, including ionic liquids, vegetable and mineral oils, water, and PEG, were introduced into supercritical CO2, and tribological tests were performed on a CNC lathe to analyze their influence on Ti6Al4V/WC-Co contact. Forces and temperatures were recorded to compare the perfomances of the scCO2-lubricant mixtures for future use in machining. The analysis of the apparent friction coefficient and sticking zone showed a noticeable decrease by ionic liquids when combined with scCO2 at a speed of 100 m/min and 4 mL/min delivery flow rate. The other lubricants (water and PEG vegetable oils) performed similarly to standard mineral oil and are less expensive, which could help in developing future low-cost yet effective cooling and lubrication methods for the machining industry.

Theoretical analysis of the piston ring-pack for predicting friction and power loss in an internal combustion engine

The piston ring is considered an essential element in the operation of the internal combustion engine to improve its efficiency and reduce its emissions. It is resistant to high temperature and high-pressure gases in the combustion chamber. A one-dimensional analysis method of lubrication between piston rings and cylinder liner in mixed lubrication conditions is developed in this article by using the GT-Suite simulation software. We applied the finite difference numerical method to solve the Reynolds equation to obtain the variation during an engine cycle of the following parameters; film thickness, frictional force, and power loss. The solution results presented can be used to improve the design of the piston ring pack in internal combustion engines and is available for industry usage.

Minimum quantity lubrication grinding process for high aluminum-silicon glass mobile phone cover plates

PurposeThe impact on both the environment and operator health is significant. As high-alumina silica glass finds applications in smart devices such as curved mobile phone screens, the grinding of complex curved surfaces necessitates cleaner and more efficient cooling and lubrication methods to enhance processing quality and improve grinding yield rates. This study aims to focus on grinding high-alumina silica glass using micro-lubrication technology and compares its performance with traditional cutting fluid cooling methods.Design/methodology/approachIn the fabrication of mobile phone cover plates composed of high-alumina silicon glass, the incorporation of micro-lubrication grinding technology was undertaken, with the conventional cutting fluid cooling approach serving as the benchmark control group for comparative analysis.FindingsThe results indicate that increasing the spray pressure of micro-lubrication within a specific range contributes to reducing grinding surface roughness. At a grinding speed ranging from 25 to 35 m/s, using micro-lubrication can effectively replace the traditional cutting fluid cooling method, resulting in glass surfaces with roughness levels between 0.22 and 0.26. However, at grinding speeds exceeding 35 m/s, the insufficient pressure of the micro-lubricant mist hinders most of the oil mist from entering the grinding zone, leading to inferior cooling performance compared to cutting fluid cooling. Notably, at a grinding speed of 35 m/s, micro-lubrication demonstrates better effectiveness in suppressing chipping during glass grinding compared to traditional cutting fluid cooling methods.Originality/valueThrough the application of micro-lubrication grinding technology, a marked improvement in the grinding quality of high-alumina silicon mobile phone cover plate glass can be achieved, leading to a reduction in surface roughness, a decrease in processing defects and ultimately satisfying the demands for high-precision and high-quality fabrication of such cover plates.Peer reviewThe peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-08-2024-0297

Addressing thermal challenges in hydrodynamic bearings: A contemporary review of strategies and technologies

Hydrodynamic bearings are integral components in various industrial sectors, including aerospace, defense technologies, and power generation units etc. Advancements in modern technology have driven the evolution of bearings to withstand the high temperatures, increased speeds, and additional load demands of contemporary operations. Some of the prime consequences of high temperatures include thermal deformation, misalignment, viscosity degradation, reduced oil film thickness, reduced load carrying capacity and premature failure due to bearing seizure. Researchers have rigorously addressed the persistent thermal challenges posed to hydrodynamic bearings, achieving significant advancements over the years. Key developments include innovative bearing pad designs, optimal materials, coating technologies, advanced computational software, novel lubrication methods, and efficient monitoring techniques. The introduction of materials with tailored properties such as high heat conductivity, high strength, and low-friction coatings has greatly enhanced bearing performance. Additionally, advanced computational software like ANSYS CFX, Fluent, and COMSOL, adaptive lubrication methods, and real-time temperature sensors have significantly improved the performance of critical systems, including hydro power plants. This review paper summarizes significant developments and investigations carried out to mitigate thermal effects in hydrodynamic bearings, and hence provides a comprehensive in depth details of the subject matter. Even though there has been a lot of progress in the field of hydrodynamic bearings, continuous research is important to tackle issues related to sustainability, industry-specific obstacles, developing technologies, and dynamic operating conditions.

Effect of Lubricated Liquid Carbon Dioxide (LCO2 + MQL) on Grinding of AISI 4140 Steel

This paper investigates the potential of utilizing lubricated liquid carbon dioxide (LCO2 + MQL) as an alternative to conventional flood cooling in grinding operations. This approach could facilitate a transition towards fossil-free production, which is a significant challenge in industry. The alternative cooling–lubrication method relies on pre-mixed LCO2 and oil and a single-channel minimum quantity lubrication (MQL) delivery method, which has already demonstrated potential in machining with geometrically defined cutting edges. However, this method has been less explored in grinding. This study primarily evaluates the grindability of AISI 4140 steel, examining surface roughness, residual stresses, microhardness, grinding forces, and specific energy for different cooling–lubrication methods. The results indicate that LCO2 + MQL is capable of attaining surface roughness and microhardness that is comparable to that of conventional flood cooling, especially in the case of less aggressive, finish grinding. Nevertheless, the presence of higher tensile residual stresses in rough grinding suggests that the cooling capability may be insufficient. While the primary objective was to evaluate the technological viability of LCO2 + MQL in terms of grindability, a supplementary cost-effectiveness analysis (CEA) was also conducted to assess the economic feasibility of LCO2 + MQL in comparison to conventional flood cooling. The CEA showed that the costs of both the cooling–lubrication methods are very similar. In conclusion, this study offers insights into the technological and economic viability of LCO2 + MQL as a sustainable cooling–lubrication method for industrial grinding processes.

Investigating the performance of the pressurized injection lubrication technique in the turning process

Efficient lubrication and cooling are crucial in machining operations to enhance tool life and workpiece quality. Sustainable methods like minimum quantity lubrication (MQL) and dry cutting often face limitations in cooling efficiency and chip evacuation, especially under high-speed conditions or when machining difficult-to-cut materials such as stainless steel. This study introduces the novel pressurized injection lubrication (PIL) technique designed to address these challenges by optimizing lubrication, cooling, and chip evacuation during the turning operations of stainless steel 304. Using flaxseed oil as the lubricant, the PIL system employs a 0.26 mm stream diameter at a pressure of 16 bar to provide the necessary cooling and lubrication to the cutting zone. Cutting temperature and surface roughness were selected as the primary responses. Experimental runs were designed using the Taguchi L9 method. Analysis of variance showed that the lubrication method significantly affected the cutting temperature, with a contribution percentage approaching 94%. The experimental results demonstrated that PIL reduced the cutting temperature by up to 55%, while MQL reduced it by about 48%, both compared to dry cutting at the highest utilized speed. The lubrication method was also found to be the most significant factor affecting surface roughness, with a contribution percentage of 72.8%. Experimentally, PIL improved surface roughness by a maximum of 16.2% compared to MQL. Additionally, PIL maintained low oil consumption (0.9 l/h) and energy usage (< 0.017 kWh). The cost-effective PIL setup, priced under 65 USD, underscores its potential as a sustainable and efficient alternative for machining processes. The system’s components are readily available, facilitating easy integration into existing metal-cutting machines. Finite element analysis (FEA) modeling was used to predict residual stresses under different lubrication methods. The FEA model indicated that PIL and MQL reduced residual stresses by about 81.2% and 76.6%, respectively, compared to dry cutting at a speed of 500 rpm. These findings suggest that PIL can significantly enhance machining performance and sustainability, offering a viable solution to modern manufacturing challenges.

Nanofluid minimum quantity lubrication assisted grinding force model considering anisotropy of SiCf/SiC ceramic matrix composites

SiCf/SiC ceramic matrix composites with excellent thermal stability, light weight and oxidation resistance have become key components in advanced aircraft engines. Nanofluid minimal quantity lubrication (NMQL) exhibits significant potential in enhancing heat transfer and lubrication efficiency during the grinding process. The technological challenge lies in thoroughly investigating the theoretical variation rule of grinding force, assisted by nanofluid minimal quantity lubrication, and subsequently achieving low-damage machining of SiCf/SiC composites. In this study, a prediction model for the grinding force during NMQL-assisted grinding was established, integrating diverse lubrication methods, grinding wheel geometric parameters, wear degree, process parameters, the anisotropy and damage degree of SiCf/SiC composites. The model was subsequently experimentally validated through grinding tests conducted on SiCf/SiC composites under various conditions, including dry grinding (DG), flood grinding (FG), minimum quantity lubrication (MQL), and carbon nanotube nanofluids (NMQL-CNTs), across multiple grinding depths. The present investigation’s grinding force forecasting model is evidenced to possess high accuracy of precision, showcasing mean deviations of 6.64 % and 11.97 % in the perpendicular (Fn) and tangential (Ft) grinding force components, respectively. Additionally, employing NMQL-CNTs facilitates the achievement of minimal grinding force and surface finish quality. At depths of 0.4 mm and 0.6 mm during grinding, the mean Fn magnitudes under the NMQL-CNTs lubrication approach underwent a decrease of 66.7 % and 74.5 %, respectively, in contrast, the mean Ft magnitudes experienced a reduction of 55 % and 67.2 %, correspondingly, in comparison to the DG lubrication technique. Notwithstanding the consistency in the material’s brittle removal mechanism across varying lubrication strategies, the NMQL-CNTs approach effectively alleviates fiber abrasion. Concisely, the research presented herein provides foundational theoretical insights and practical technological assistance for the achievement of low damage SiCf/SiC composite processing.

Improving the Performance of the Machining Process by Using Ultra‐Advanced Tools in a Clean Turning of Inconel 686 Using the Minimum Quantity Lubrication Method

ABSTRACTThe high tensile strength and high resistance of nickel‐based superalloy 686 against high temperatures and corrosion rates have made it a widely used in important applications such as the aerospace industry, high pollution‐ and corrosion‐resistance equipment manufacturing and petrochemical industry. Therefore, the machining of this advanced alloy with its unique properties is extremely important and can be challenging. Significant increase in input parameters levels, reduction of machining costs, improvement of surface and subsurface properties and clean production are among the issues that should be considered in dealing with Inconel 686 turning operations. Simultaneous application of advanced tools such as polycrystalline diamond (PCD) and polycrystalline cubic boron nitride (PCBN) and optimised minimum quantity lubrication (MQL) method and evaluating the results obtained with a wide range of output parameters related to machining process performance and tribological properties can be proposed as an innovation and a solution to this problem in this article. This study analyses several output parameters with different speeds and feeds to evaluate the effect of cutting insert type on machining process performance and tribological properties. The output parameters include tool wear, residual stress, cutting zone temperature, surface smoothness, machining forces and workpiece surface defects. The results indicated that using the optimised MQL method reduces the size of lubricant droplets and increases the surface covered by cooling. With these changes, the performance of the machining process and the parameters related to the surface integrity increase significantly. Among the parameters associated with the performance of the machining process, the PCD tool reduces the cutting zone temperature by 23%, the tool wear by 19% and the machining forces by 18% compared to the PCBN tool. In the parameters related to surface integrity, this method reduces the residual stress by 19% and the surface roughness by 9% compared to the PCBN tool. From the production index perspective, the PCD tool can significantly increase the cutting speed and feed rate, reducing production time and costs.

Digitally enhanced development of customised lubricant: Experimental and modelling studies of lubricant performance for hot stamping

Digitally enhanced technologies are transforming every aspect of the manufacturing sector towards the era of digital manufacturing. Traditional lubricant development methods involving systematic but time-consuming iterative processes is still extensively used in the metal forming industry. In the present study, a novel digitally enhanced lubricant development scheme was proposed by leveraging a mechanism-based interactive friction modelling framework and quantitative and comprehensive evaluation of lubricant performance via the data-centric lubricant limit diagrams. By predicting transient lubricant behaviour following the complex contact condition evolution experienced in actual forming operations, a close association and quantified relation between the lubricant performance and its properties such as viscosity, evaporation rate and fraction of dry matter was established. This can facilitate the optimisation efficiency of lubricant parameters and minimise the experimental cost for iterative lubricant trials. A case study was conducted in this work to develop a customised lubricant using this digitally enhance scheme for the target hot stamping process based on a benchmark lubricant as a reference. Further industrial forming tests of an automotive component were conducted to validate the ideal performance of the customised lubricant.

A Short Review on Minimum Quantity Lubrication Method in Machining Applications

A Short Review on Minimum Quantity Lubrication Method in Machining Applications

Influence of Lubrication Cycle Parameters on Hydrodynamic Linear Guides through Simultaneous Monitoring of Oil Film Pressure and Floating Heights

Hydrodynamic linear guides in machine tools offer a high load capacity and excellent damping characteristics, improving stability, precision, and vibration reduction. This study builds on previous research where floating heights were verified with a simulation model limited to measured floating heights. Advancements include incorporating pressure sensors into a fixed steel rail, enabling simultaneous measurement of oil film pressure and floating heights for a comprehensive understanding of lubrication conditions within the lubrication gap. The experimental results explore the effects of different lubrication methods, providing valuable insights into cavitation and lubrication adequacy. The results demonstrate the feasibility of utilizing pressure sensors to measure oil film pressure within the lubrication gap, providing a nuanced understanding of lubrication dynamics. By measuring both floating heights and pressure measurement, distinctions between hydrodynamic lubrication, mixed friction regions, and instances of lubricant deficiency become readily discernible. The variations in real-time oil film pressure and floating heights help to optimize the lubrication cycle for hydrodynamic linear guides, enhancing system performance and longevity.

Scalable Preparation of Liquid Infused Coatings for Lubrication of 103 m2 Dry Ski Slopes.

To facilitate effective training for freestyle skiers on artificial dry ski slopes, it is crucial to reduce the friction coefficient of the slopes and closely match it with that of snow. Traditional lubrication methods, such as water or soapy water, come with multiple disadvantages, including water waste, which leads to environmental pollution, short-lived effectiveness, and high costs. In this study, we have successfully developed a method for the scalable preparation of a liquid-infused coating (LIC) by tandem spraying inexpensive and environmentally friendly SiO2 particles and silicone oil lubricants. Experimental results showed that the resulting LIC is capable of imparting slippery properties to various surfaces, regardless of the surface chemistry. Moreover, the presence of LIC could reduce the friction coefficient significantly. By carefully regulating the surface composition, we achieved a friction coefficient of 0.059 between a snowboard and the LIC-functionalized ski slope, closely matching that between the snowboard and snow in a typical skiing competition venue (∼0.06). We successfully applied LIC onto 103 m2 dry ski slopes, providing a training ground for professional freestyle skiers.

Newtonian flow with slip and pressure-drop predictions in hyperbolic confined geometries

We study theoretically the steady Newtonian flow in confined and hyperbolic long tubes (symmetric channels and axisymmetric pipes) considering slip along the walls. Using a stream function formulation, and the extended (or high-order) lubrication method in terms of the square of the aspect ratio of the tube, ε, the solution for the stream function is found analytically up to twentieth order in ε. At the classic lubrication limit, i.e. i.e. for a vanishing small aspect ratio, and for perfect slip conditions, the analysis predicts a plug-like velocity profile and a constant strain-rate on the midplane/axis of symmetry of the tube. A constant strain-rate is also predicted for the non-slip case. Furthermore, the high order asymptotic results for the stream function and fluid velocity are post-processed with an acceleration technique to investigate the convergence and accuracy of the solution. The results reveal the existence of a boundary layer at the inlet of the tube, the influence of which diminishes in a very short distance from the entrance. We discuss the effect of the contraction ratio of the tube and the dimensionless slip coefficient on the midplane/centerline and wall (slip) velocities, as well as on the average pressure-drop, required to maintain a constant flow-rate. The acceleration of converge technique on the solution for the pressure-drop revealed a remarkable convergence at a value slightly larger (∼1 %) than the value predicted by the classic lubrication theory. Finally, we comment on the common practice in the literature for approaching the velocity profile with the velocity profile at the classic lubrication limit, and we compare the high-order results for the strain rate at the midplane/centerline with the effective strain rate previously derived in the literature by Housiadas & Beris, J. Rheology, 68(3), 327–339, 2024.

In pursuit of sustainability in machining titanium alloys using phosphonium-based halogen-free ionic liquids as potential metalworking fluid additives

In recent years, researchers have investigated ionic liquids (ILs) as suitable metalworking fluids (MWFs) additive. Most commonly used ILs contain halogen anions, which creates issues related to corrosion and toxicity. However, phosphonium-based halogen-free ILs (HF-ILs) provide a safer alternate with enhanced biodegradability and minimal adverse effects on the environment. This research examines the potential of HF-ILs as an additive to canola oil. In this research two halogenated ILs [BMIM][PF6]- and [BMIM][BF4]- and one halogen-free IL ([P6,6,6,14][i(C8)2PO2]-) were added 1 % by volume in canola oil. First, the thermophysical properties of these synthesized MWFs were evaluated. Result concluded that the HF-ILs reduced contact angles on both the workpiece and the cutting tool surfaces by 12– 15 % compared to pure canola oil. Whereas, improved the thermal conductivity by 10.5 %. Furthermore, the machining operation was carried out at two cutting speeds (80 and 100 m/min) and feed (0.1 and 0.2 mm/rev) to analyse the effect of synthesized MWFs under the minimum quantity lubrication method. Findings concluded that phosphonium-based halogen-free IL showed better cutting performance, with reduction in tool wear, cutting temperature by 10–33 %, and surface roughness by 34−46 %. Additionally, this approach supports a "greener" and more sustainable work environment by lowering MWF consumption by using minimal quantity lubrication, reducing tool wear and surface roughness which helps in cost reduction and product rejection for any manufacturing industry.

Tablet ejection: A systematic comparison between force, static friction, and kinetic friction

The magnitude of the frictional forces during the ejection of porous pharmaceutical tablets plays an important role in determining the occurrence of tabletting defects. Here, we perform a systematic comparison between the maximum ejection force, static friction coefficient, and kinetic friction coefficient. All of these metrics have different physical meanings, corresponding to different stages of ejection. However, experimental limitations have previously complicated comparisons, as static and kinetic friction could not be measured simultaneously. This study presents a method for simultaneously measuring the maximum ejection force, static friction coefficient, and kinetic friction coefficient in situ during tablet ejection in routine compaction simulator experiments. Using this method, we performed a systematic comparison, including variations of (1) ejection speed, (2) compaction pressure, (3) material, and (4) lubrication method. The relative importance of each variable is discussed in detail, including how ejection speed alone can be a decisive factor in tablet chipping. The reliability of the newly developed method is supported by excellent agreement with previous studies and finite element method (FEM) simulations. Finally, we discuss the suitability of friction coefficients derived from Janssen–Walker theory and explanations for the phenomenon of die-wall static friction coefficients with apparent values far above unity.

Influence of Al2O3 nanoparticle mass concentration and aerosol formation parameters on tool vibration during turning of Ti6Al4V titanium alloy

Machining difficult-to-cut materials involves challenging machining conditions, including higher temperatures in the cutting zone, cutting forces and friction. Another important phenomenon is vibration, which is undesirable when manufacturing high quality workpieces. One way to reduce vibration in the cutting zone is to use cooling methods. Due to its environmentally friendly nature, the minimum quantity lubrication (MQL) method has already been widely used in metalworking. However, when combined with nanofluids, it improves the ability of the aerosol to dissipate more heat and increase lubrication in the cutting zone. This paper presents the effect of a polyol ester-based Al2O3 nanofluid due to the varying mass concentration of nanoparticles on the vibration during turning of Ti6Al4V alloy and compares the results with dry cutting and the MQL method without nanoparticles. Four concentrations (0.25−1 wt%), variable nanofluid flow rate E = 0.388−1.182 g/min and air flow rate P = 10−40 l/min were considered. According to the statistical analysis, the most important factor influencing tool vibration was the mass concentration of nanoparticles in the cutting fluid. By combining the MQL method with 0.5 wt% Al2O3, the vibration acceleration RMS values were found to be the lowest. When compared to the MQL method without nanoparticles, the RMS values for dry cutting ranged from 17.8% to 24.9%, and for wet cutting they were reduced by about 10.9-18.5%.

Machinability investigation of grinding 2.5D-SiCf/SiC composites under nanofluid minimum quantity lubrication

SiCf/SiC composites are now the preferred option for the thermal structures of next-generation advanced aero-engines, owing to their high-temperature strength, and creep resistance. Grinding is currently a highly reliable and mature method for SiCf/SiC processing. However, the harsh, dry machining conditions lead to degradation of surface quality, and the dust generated can harm both humans and the environment. Nanofluid Minimum Quantity Lubrication (NMQL) maximizes heat transfer and lubrication in grinding and is environmentally and human-friendly. Based on this, this study thoroughly investigates the effects of dry, flood grinding, minimum quantity lubrication, and different nanofluids (MoS2 and carbon nanotubes (CNTs)) on grinding performance at different grinding depths. Compared with dry grinding, the results show that the normal grinding component force Fn is reduced by 56.9 %, 56.8 %, and 71.6 %, and the tangential grinding component force Ft is reduced by 48.4 %, 50.5 %, and 57.5 % for NMQL-CNTs lubrication condition at grinding depths of 0.2 mm, 0.4 mm, and 0.6 mm, respectively. Meanwhile, NMQL-CNTs can significantly improve the surface quality and help to obtain a surface morphology with fewer surface defects, and the stabilized lubricant film formed by NMQL-CNTs can significantly reduce the specific grinding energy. Although brittle removal was observed in different lubrication methods, NMQL-CNTs could significantly reduce surface damage due to their filling and friction reduction effects. Due to the high viscosity of NMQL-CNTs and the low intermolecular forces, they have strong lubrication stability and wear resistance. This study provides theoretical guidance for the green processing of SiCf/SiC composites.

Newton-GMRES Method for Thermal Elasto-hydrodynamic Lubrication of Line Contact Problems

Newton-GMRES Method for Thermal Elasto-hydrodynamic Lubrication of Line Contact Problems

Achieving underwater stable drag reduction on superhydrophobic porous steel via active injection of small amounts of air

Over the years, numerous researchers have proposed air lubrication methods to reduce drag in underwater vehicles. This method is challenged by buoyancy and water flow, which facilitate air escape from solid surfaces, necessitating substantial air to achieve significant drag reduction. The adherence of hydrophobic interfaces to submerged air bubbles reduces air escape, stabilizing it on solid surfaces for effective drag reduction. However, high flow velocities or pressure conditions can destabilize the drag reduction effect by disrupting the air-water interface. To address this issue, the paper proposes a method that integrates superhydrophobic surfaces with active air injection. This approach involves preparing stable superhydrophobic surfaces by combining laser ablation, heat treatment, and spraying hydrophobic coatings on porous steel surfaces, and using active air injection to maintain the stability of the air layer. Flow field analysis revealed that active air injection into superhydrophobic porous steel sustains a stable air layer, even at high flow velocities, reaching a drag reduction exceeding 25%. Moreover, at high Reynolds numbers, high drag reduction can be achieved at significantly low flow rates compared to smooth surface. This approach shows promise for maintaining a stable air-water interface on superhydrophobic surfaces and sustaining drag reduction in engineering applications.