A novel precision vibration-assisted micro-engraving system was developed by the integration of fast tool servo and ultrasonic elliptical vibration system, in which the flexure hinge was designed to avoid backlash and PID control algorithm was established to guarantee specific precision. Apart from experimental validation of the performance of the system, various micro-V-grooves cutting experiments on aluminum alloy, ferrous material and hard cutting material were performed, in which Kistler force sensor was used to measure cutting force. Through experiments, it was clear that the vibration-assisted micro-engraving system can ensure good quality of micro-V-grooves and reduce cutting force by about 60% compared with traditional removal process without ultrasonic vibration.
It is well known that shark skin surface can effectively inhabit the occurrence of turbulence and reduce the wall friction, but in order to understand the mechanism of drag reduction, one has to solve the problem of the turbulent flow on grooved-scale surface, and in that respect, the direct numerical simulation is an important tool. In this article, based on the real biological shark skin, the model of real shark skin is built through high-accurate scanning and data processing. The turbulent flow on a real shark skin is comprehensively simulated, and based on the simulation, the drag reduction mechanism is discussed. In addition, in order to validate the drag-reducing effect of shark skin surface, actual experiments were carried out in water tunnel, and the experimental results are approximately consistent with the numerical simulation.
