An ultra-elliptical surface product and a method for manufacturing the same

Abstract

The application discloses an ultrahyperellipse surface product and a preparation method thereof. The processing shape of the ultrahyperellipse surface is consistent with a theoretical numerical shape. The ultrahyperellipse surface is processed by laser direct writing, and the geometric shape and spatial properties of the ultrahyperellipse surface are regulated by parameter design of a theoretical ultrahyperellipse equation and laser processing parameter design. The processing method of the ultrahyperellipse surface has universality, and can be used for processing on the surface of a substrate of different materials by using a laser. The ultrahyperellipse surface and the processing method thereof can be widely applied to the fields of aerospace, chip manufacturing, micro-nano processing, surface science and the like.

Description

Technical Field

[0001] This invention belongs to the field of surface processing technology and relates to a superelliptical surface product and its preparation method. Background Technology

[0002] Laser processing is a typical subtractive manufacturing process that weakens the structural mechanical strength of the substrate material. Therefore, special consideration must be given to its impact on the substrate's mechanical properties to avoid severe stress concentration during later use, which could lead to a weakened substrate and reduced mechanical stability, weather resistance, and durability. Typically, the mechanical stability of a microstructure is determined by its geometry. Traditional laser-processed substrates often have circular or square surfaces. Circular surfaces offer the advantage of uniform stress distribution, but their low surface area ratio relative to the material surface results in low surface utilization, which is detrimental to the packaging quantity and density of functional materials and electronic components. Square surfaces offer the advantage of a high surface area ratio, but their sharp corners cause stress concentration, leading to poor mechanical stability and susceptibility to damage under external forces (such as tension and bending), making long-term use difficult. Therefore, it is necessary to design a geometric shape that combines high surface utilization and high mechanical stability for laser-processed surface technology, expanding its applications in aerospace, chip manufacturing, micro / nano fabrication, and surface science. Summary of the Invention

[0003] To address the problems existing in current laser-processed surface technologies, this invention designs a superelliptical surface product and its preparation method. A superellipse is a geometric shape between a circle and a square; the curved transitions at the corners effectively reduce stress concentration and increase the unit area ratio of the laser-processed surface, thus achieving both high mechanical stability and high surface utilization. This invention discloses superelliptical surface designs and preparation techniques for different applications, detailing a series of superelliptical parameter designs. The superelliptical surface can be laser-processed on substrates of various materials, and the processed shape conforms to the theoretical shape, demonstrating universality.

[0004] The preparation technology solution of this invention is as follows:

[0005] A superelliptical surface article, wherein the superelliptical surface article has a superelliptical surface structure that conforms to the following curve equation:

[0006]

[0007] Among them, the shape parameters include: n is an exponential parameter, with a value range from 2 to positive infinity; a and b are semi-diameter parameters.

[0008] Furthermore, when the semi-diameters of the hyperelliptical surface are equal (a = b), the design exponent parameter n ranges from 2 to positive infinity. When n is close to 2, the hyperelliptical trajectory equation tends towards a circle; when n is close to positive infinity, the hyperelliptical trajectory equation tends towards a square.

[0009] The equation for the area of ​​the hyperellipse is as follows:

[0010]

[0011] Where S is the area of ​​the hyperellipse. Furthermore, to simplify the calculation, two equations are introduced:

[0012] Γ is the Gamma equation, and its general formula is:

[0013] B is the Beta equation, and its general formula is: When a = b, the equation for the area of ​​the hyperellipse becomes:

[0014]

[0015] At this point, the surface shape enclosed by the centers of any four adjacent hyperellipses (top, bottom, left, and right) constitutes the smallest repeating unit. The area percentage of the hyperellipse within a repeating unit is:

[0016]

[0017] Where d is the hyperellipse spacing, which is the distance between the edges on the central axis of any two adjacent hyperellipses, A is the area of ​​a repeating unit, and σ is the hyperellipse surface utilization rate.

[0018] The method for preparing the hyperelliptical surface includes the following steps:

[0019] Step 1: Select a substrate of different materials according to different application requirements. The substrate can be an organic material or a metal material. Then, perform dimensional processing and surface pretreatment.

[0020] Step 2: Theoretically design the shape parameters n, a, b of the hyperellipse and the spacing d between adjacent hyperellipses, and then draw the laser processing diagram according to the design parameters, calculate the surface utilization rate of the hyperelliptical surface and simulate the surface stress distribution.

[0021] Step 3: Prepare the sample surface using a laser processing system according to the design drawings;

[0022] Step 4: Verify the preparation results of the hyperelliptical surface through surface morphology observation and characterization methods;

[0023] Step 5: If the processed shape does not match the theoretical design, iterative design and processing are required. This iterative design and processing refers to returning to step 3 to change the laser processing parameters until the processed shape matches the theoretical design.

[0024] Furthermore, the selection of the substrate material for the superelliptical surface is determined by comprehensively considering various factors such as the substrate's material, thickness, density, strength, hardness, and cost, based on the application scenario and usage requirements.

[0025] Furthermore, when the superelliptical surface substrate is processed using organic materials, its properties are: thickness 1-300mm, density 1.14-1.20g / cm³. 3 Young's modulus 3.1-4.0 GPa, tensile strength 50-77 MPa, flexural strength 90-130 MPa, melting point 130-140℃, Poisson's ratio 0.3-0.4.

[0026] Furthermore, when the superelliptical surface substrate is processed using a metallic material, its properties are: thickness 0.1-3 mm, density 2.63-2.85 g / cm³. 3 Young's modulus 65-80 GPa, tensile strength 110-650 MPa, flexural strength 150-400 MPa, Poisson's ratio 0.3-0.4.

[0027] Furthermore, the pretreatment of the superelliptical surface involves ultrasonic cleaning for 5-15 minutes, followed by drying with high-pressure air for 1-2 minutes until dry.

[0028] Furthermore, the parameters of the hyperelliptical surface are designed such that the exponent n is 2-10, the semi-diameters a and b are 50-500μm, and the spacing d is 10-1000μm.

[0029] Furthermore, the formula for calculating the surface utilization rate σ of the hyperelliptical surface is as follows:

[0030]

[0031] The higher the corresponding value, the higher the surface utilization rate.

[0032] Furthermore, the stress distribution on the hyperelliptical surface is simulated using the software ABAQUS to determine the stress distribution of a single hyperelliptical structure under biaxial tension. The maximum Von Mises stress near the hyperelliptical microstructure is used as the criterion for judging the magnitude of the stress concentration effect; the larger the corresponding value, the more severe the stress concentration effect.

[0033] Furthermore, the superelliptical surface substrate is laser-processed with a scanning speed of 1-1000 mm / s, a laser frequency of 1-1000 kHz, and a laser power of 1-80 W.

[0034] Furthermore, the hyperelliptical surface is observed and verified using an optical microscope until the dimensions and shape of the surface-processed structure meet the customized requirements and conform to the design pattern guided by parameters n, a, and b. Specifically, for the hyperelliptical surface shape, when a and b are equal, as the value of parameter n increases, the surface utilization rate σ increases, while the stress concentration at the corners becomes more concentrated, resulting in poorer structural mechanical properties.

[0035] The beneficial effects of this invention are that, for materials with poor mechanical strength (such as organic materials), a hyperelliptical shape with a smaller n-value can be selected, resulting in less stress concentration and prioritizing surface mechanical strength; for materials with high mechanical strength (such as metallic materials), a hyperelliptical shape with a larger n-value can be selected, prioritizing high surface utilization. By comprehensively considering the characteristics of the substrate material, surface utilization, stress concentration effect, and structural mechanical strength, different substrate materials and parameter values ​​(n, a, b) can be selected according to different needs, resulting in different surface utilization, stress concentration effects, and structural strengths. This allows for the design of hyperellipses of different materials and shapes to meet specific requirements, broadening the application range and applicable conditions of the product. Attached Figure Description

[0036] Figure 1 These are schematic diagrams of different shapes of unit hyperellipse trajectories. Example 1 uses a hyperellipse trajectory with n=3; Example 2 uses a hyperellipse trajectory with n=8.

[0037] Figure 2 This is a schematic diagram of the dimensional design parameters for the hyperelliptical design in Example 1.

[0038] Figure 3 This is a simulation diagram of the hyperelliptical stress distribution in Example 1.

[0039] Figure 4 This is a characterization diagram of the hyperelliptical surface morphology in Example 1.

[0040] Figure 5 This is a simulation diagram of the hyperelliptical stress distribution in Example 2. Detailed Implementation

[0041] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0042] Figure 1 This is a schematic diagram of the trajectory of a unit hyperellipse in different shapes. For example... Figure 1 As shown, a superelliptical surface article has a surface structure with a superelliptical geometry, and its curve equation is:

[0043]

[0044] Where n is the exponential parameter, and a and b are the semi-diameter parameters. Figure 1 The diagram shows the shape of the hyperellipse when a = b = 1 and n takes the values ​​2, 3, 4, ..., 10. When n takes the value ∞, the trajectory of the equation is a square.

[0045] Example 1

[0046] A superelliptical surface, with a substrate processed from organic material acrylic (polymethyl methacrylate), has the following properties: density 1.19 g / cm³. 3 It has a Young's modulus of 3.6 GPa, a tensile strength of 60 MPa, a flexural strength of 110 MPa, a melting point of 130℃, and a Poisson's ratio of 0.4.

[0047] Its preparation method is as follows:

[0048] Step 1: Use a CNC machine tool to process the organic sheet into a size of 20×20×3mm. 3 ;

[0049] Step 2, surface pretreatment involves ultrasonic cleaning for 10 minutes, followed by drying with high-pressure air for 2 minutes until dry;

[0050] Step 3, as follows Figure 2 As shown, the parameters of the hyperelliptical surface are designed with an exponent n of 3, half-diameters a and b of 250 μm, and spacing d of 25 μm.

[0051] Step 4, calculate the surface utilization rate σ of the hyperellipse, which is 80.12%; if Figure 3 As shown, the maximum Von Mises stress on the simulated surface is 24.960 MPa;

[0052] Step 5: The organic board is laser-processed at a scanning speed of 800 mm / s, a laser frequency of 20 kHz, and a laser power of 25 W to form the superelliptical surface.

[0053] Step 6, then characterize the morphology of the hyperelliptical surface, such as... Figure 4 As shown, the shape is compared with the theoretical design pattern of n=3, verifying that the shape conforms to the design, and the preparation of the superelliptical surface is completed.

[0054] Example 2

[0055] A super-elliptical surface, with a substrate made of aluminum alloy, has the following properties: density 2.81 g / cm³. 3 Young's modulus 71.7 GPa, tensile strength 572 MPa, flexural strength 385 MPa, Poisson's ratio 0.33.

[0056] Its preparation method is as follows:

[0057] Step 1: Use a CNC machine tool to process the metal sheet into a size of 20×20×0.1mm. 3 ;

[0058] Step 2, surface pretreatment involves ultrasonic cleaning for 15 minutes, followed by drying with high-pressure air for 1 minute until dry;

[0059] Step 3: The parameters of the hyperelliptical surface are designed as follows: exponent n is 8, semi-diameters a and b are 250 μm, and spacing d is 50 μm.

[0060] Step 4, the surface utilization rate σ of the hyperellipse is calculated to be 88.75%, as shown below. Figure 5 As shown, the maximum Von Mises stress on the simulated surface is 27.356 MPa;

[0061] Step 5: The aluminum alloy is laser-processed at a scanning speed of 1000 mm / s, a laser frequency of 1000 kHz, and a laser power of 80 W to form the superelliptical surface.

[0062] It should be noted that, according to the above embodiments of the present invention, those skilled in the art can fully realize the scope of the independent claims and dependent claims of the present invention, and the implementation process and methods are the same as those in the above embodiments; and the parts of the present invention not described in detail belong to the well-known technology in the art. The above description is only some specific embodiments of the present invention, but the protection scope of the present invention is not limited thereto. Any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the protection scope of the present invention.

Claims

1. A method for preparing products with superelliptical surfaces, characterized in that, The superelliptical surface article has a superelliptical surface, and the superelliptical surface structure conforms to the following curve equation: Where n is the exponent parameter; a and b are the semi-diameter parameters; the parameters of the hyperelliptical surface are designed such that the exponent n is 2-10, the semi-diameter a is 50-500 μm, and the semi-diameter b is 50-500 μm; the equation for the hyperelliptical area is as follows: ， Where S is the area of ​​the hyperellipse; The Gamma equation has the following general formula: , The Beta equation has the following general formula: ; The method includes the following steps: Step 1: Select a substrate of different materials according to different application requirements. The substrate can be an organic material or a metal material. Then, perform surface pretreatment on the substrate. Step 2: Theoretically design the shape parameters n, a, b of the hyperellipse and the spacing d between adjacent hyperellipses, and then draw the laser processing diagram according to the design parameters; calculate the surface utilization rate of the hyperelliptical surface and simulate the surface stress distribution; where the spacing d is taken as 10-1000μm; Step 3: Prepare the sample surface using a laser processing system according to the design drawing; the superelliptical surface substrate is processed with a laser scanning speed of 1-1000 mm / s, a laser frequency of 1-1000 kHz, and a laser power of 1-80 W. Step 4: Verify the preparation results of the hyperelliptical surface through surface morphology observation and characterization methods; Step 5: If the processed shape does not match the theoretical design, iterative design and processing are required. The iterative design and processing refers to returning to step 3 to change the laser processing parameters until the processed shape matches the theoretical design. When organic materials are used to process the superelliptical surface substrate, the properties of the superelliptical surface product are: thickness 1-300mm, density 1.14-1.20g / cm³. 3 Tensile strength 50-77MPa, flexural strength 90-130MPa; When the superelliptical surface substrate is processed using metallic materials, the properties of the superelliptical surface product are: thickness 0.1-3mm, density 2.63-2.85g / cm³. 3 Tensile strength 110-650MPa, flexural strength 150-400MPa.

2. The method according to claim 1, characterized in that, The selection of the substrate material for the superelliptical surface is determined by comprehensively considering various factors such as the substrate's material, thickness, density, strength, hardness, and cost, based on the application scenario and usage requirements.

3. The method according to claim 1, characterized in that, The pretreatment of the superelliptical surface involves ultrasonic cleaning for 5-15 minutes, followed by drying with high-pressure air for 1-2 minutes until dry.

4. The method according to claim 1, characterized in that, The hyperelliptical surface was observed and verified using an optical microscope until the dimensions and shape of the surface processing structure met the customized requirements and matched the graphic designed with the n, a, b parameters.

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