Micro-Nano Surface Treatment for Complex Shapes and Strong Bonding
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Solution Overview
Problem
Existing surface engineering technologies face challenges such as poor bonding strength, difficulty in coating complex shapes, low yield, low efficiency, and environmental pollution, making it hard to meet requirements of product performance, economic efficiency, and sustainability.
Innovation Solution
A micro-nano incremental mechanical surface treatment (MIMST) method that uses a modification tool with preset moving parameters, assisted by ultrasonic vibration, to compress and process the surface of a substrate material, improving bonding strength and efficiency while avoiding pollution, and allowing for complex shape modifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional coating technologies are used to modify surface, then surface properties can be improved, but bonding strength is poor and coating materials in complex shapes is difficult
Solution Approach 1:
The patent replaces conventional coating technologies with a mechanical surface treatment system that uses a modification tool to directly process the substrate surface through rotation, compression, and ultrasonic vibration, eliminating the need for separate coating materials and achieving superior bonding strength through mechanical integration
Solution Approach 2:
The modification tool is assisted by an ultrasonic vibration device that applies high-frequency vibrations during the surface treatment process, enhancing the mechanical action mode and enabling effective processing of complex-shaped surfaces through the vibration-assisted compression and deformation mechanism
2Productivity
If conventional surface modification technologies are used, then surface properties can be enhanced, but treatment efficiency is low and cost is high
Solution Approach 1:
The patent employs adjustable processing parameters including tool rotating speed (1000-30000 rpm), feeding speed (1000-6000 mm/min), single-layer downward compressing amount (0.01-0.1 mm), and processing pass (10-30 times) to optimize treatment efficiency and adapt to different production requirements and cost constraints
Solution Approach 2:
The modification tool continuously processes the surface through coordinated rotation, feeding, and compression actions without interruption, maintaining continuous mechanical work on the substrate surface to maximize treatment efficiency and reduce processing time
3Reliability
If conventional surface engineering methods are used, then surface performance can be improved, but environmental pollution occurs
Solution Approach 1:
The patent replaces chemical coating and treatment processes with a purely mechanical surface treatment system that uses friction, compression, and ultrasonic vibration to modify the surface, eliminating harmful chemicals and environmental pollution while achieving superior surface performance
Solution Approach 2:
The modification tool directly processes the substrate surface through mechanical action and ultrasonic vibration, enabling the material to self-reorganize and self-strengthen through the applied mechanical energy without requiring external chemical agents or environmentally harmful substances
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The MIMST method enhances the mechanical and physical properties of the surface layer, improves microhardness and reduces friction coefficients, achieving high bonding strength, low cost, and environmentally friendly production with efficient processing of complex shapes.
Implementation Method 1
the modification tool is assisted by an ultrasonic vibration device. A static pressure of ultrasonic vibration of the ultrasonic vibration device is in a range of 150 N to 350 N, and a vibration amplitude is in a range of 2 μm to 7 μm
Implementation Method 2
Due to the introduction of the numerical control, a computer aided technology can be sufficiently utilized, the 3D metallic structure surface micro-nano manufacturing of various complex shapes can be efficiently realized... Moreover, a mechanical action mode is adopted, that is, a Micro-nano Incremental Mechanical Surface Treatment (MIMST) process is adopted for induction, and ultrasonic excitation assistance is introduced to directly act on the surface of the material
Data Source
AI summary
A micro-nano incremental mechanical surface treatment method, comprising the following steps: using a modification tool having a designable end to contact a surface of a substrate material, rotating the modification tool in a local region and compressing the material surface, presetting processing parameters by means of 3D modeling software, and after the tool has processed the entire surface, enabling the tool to move downwards to the indented surface compressed previously. The process continues until the surface material is compressed to a pre-defined thickness, thereby achieving the goals of grain refinement and surface performance improvement. By means of the present method, a workpiece having a complex shape can be flexibly and designably surface modified. The method has the advantages of high bonding strength, no pollution, and low cost.