METHOD FOR MANUFACTURING MICRON SIZE SURFACE LUBRICANT POCKETS
Publication Date: 2015-Oct-28
The IP.com Prior Art Database
A method for manufacturing lubricant or lube pockets having lesser than 5 micron depth without burrs or debris is disclosed The method of manufacturing lube pockets comprises preparing a flat or curved sample according to requirements of application cleaning surface of the sample is in an ultrasonic bath using laser etching technique to create lube pockets or initial dimples of 150 micron and polishing or cleaning the surface using liquinox solution through ultra sonication According to one embodiment the initial dimples of 150 micron have a pitch of about 375 microns and a depth of about 4 microns Manufacturing lube pockets at top dead center TDC of a cylinder liner of an engine according to the method described herein lowers friction that leads to lower fuel consumption reduced scuffing risk and reliable and longer life of engine parts
The present disclosure relates generally to lubricant pockets on smooth surfaces and more particularly to a method for manufacturing micron size surface lubricant pockets.
Lubricant or lube pockets are generally provided on smooth surfaces to reduce friction in boundary lubrication regime of various sliding, rolling interfaces. These lubricant pockets created on smooth surfaces help in holding small quantities of oil and lubricating the interfaces under severe sliding conditions. The pockets have an advantage over other honing patterns such because lube pockets do not conduct the oil or lubricant outside of a contact patch of the interfaces and retains the oil within.
Conventional techniques provide lube pockets that are 5 to 20 microns deep and smooth surfaces are typically used in cylinder liners of internal combustion (IC) engines to reduce oil consumption. However, while lube pockets of 5 to 20 microns depth do provide benefit of reduction in friction and wear, they increase oil consumption in case of IC engines as such lube pockets hold large quantity of oil.
Lube pockets smaller 5 microns are difficult manufacture as they have debris and burr issues associated with manufacture. Additive manufacturing may be used to create lube pockets having depth less than 10 microns and micro milling can be used to create lube pockets without issues of burr and debris. However, both additive manufacturing and micro milling are very expensive and tedious processes.
It would be desirable to have a method for manufacturing lubricant pockets that are smaller than 5 microns without issues of debris and burr.
BRIEF DESCRIPTION OF DRAWINGS
Figure 1 depicts optical image of a surface after laser etching and before chemical etching according to a method of manufacturing lubricant pockets described herein.
Figure 2 depicts optical image of the surface after laser etching, chemical etching and polishing according to the method of manufacturing lubricant pockets described herein.
A method for manufacturing lubricant or lube pockets having lesser than 5 micron depth without burrs or debris is disclosed. The method of manufacturing lube pockets comprises the following steps. A flat or curved sample according to requirements of application is prepared. Surface of the sample is cleaned in an ultrasonic bath and laser etching technique is used to create lube pockets or initial dimples of 150 micron. According to one embodiment, the initial dimples of 150 micron have a pitch of about 375 microns and a depth of about...