Method and tool for producing a surface of predetermined roughness

A method for producing a surface that has a surface structure of predetermined geometry, that is suitable for application of material by thermal spraying and is in the form of a geometrically determined groove structure, the method comprising:

• introducing a first groove into a surface of a structure, said surface cylindrical, by:
• removing material from the structure by contacting the structure with at least a first cutting tool, and
• plastically deforming part of the structure by applying blunt force by contacting the surface of the structure with at least a first displacement structure,
• the first groove extending at least one revolution about an axis of the cylindrical surface.

A method for producing a surface that has a surface structure of predetermined geometry, that is suitable for application of material by thermal spraying and is in the form of a geometrically determined groove structure, the method comprising:

• forming at least a first groove having a final cross-sectional contour in a surface of a structure by sequentially contacting locations on the surface of the structure with at least a first cutting tool and a second cutting tool of a cutting plate, the cutting plate is a single unitary piece of material comprising at least the first cutting tool and the second cutting tool, the first cutting tool is a first projection, the second cutting tool is a second projection, the first projection is separate from the second projection, the first projection is spaced from the second projection, said contacting locations on the surface of the structure with the first cutting tool causing material to be removed from the structure, the first groove having a first cross-sectional contour at each said location after said contacting the structure with the first cutting tool, said contacting the structure with the second cutting tool causing material to be removed from the structure, the first groove having a second cross-sectional contour at each said location after said contacting the structure with the second cutting tool,
• the final cross-sectional contour comprising a portion of the first cross-sectional contour and a portion of the second cross-sectional contour,
• wherein said method comprises plastically deforming the structure, thereby constricting an opening of the first groove.

A method for producing a surface that has a surface structure of predetermined geometry, that is suitable for application of material by thermal spraying and is in the form of a geometrically determined groove structure, the method comprising:

• forming at least a first groove having a final cross-sectional contour in a surface of a structure by sequentially contacting locations on the surface of the structure with at least a first cutting tool and a second cutting tool of a cutting plate, the cutting plate is a single unitary piece of material comprising at least the first cutting tool and the second cutting tool, the first cutting tool is a first projection, the second cutting tool is a second projection, the first projection is separate from the second projection, the first projection is spaced from the second projection, said contacting locations on the surface of the structure with the first cutting tool causing material to be removed from the structure, the first groove having a first cross-sectional contour at each said location after said contacting the structure with the first cutting tool, said contacting the structure with the second cutting tool causing material to be removed from the structure, the first groove having a second cross-sectional contour at each said location after said contacting the structure with the second cutting tool,
• the final cross-sectional contour comprising a portion of the first cross-sectional contour and a portion of the second cross-sectional contour,
• wherein in said contacting locations on the surface of the structure with the first cutting tool of the cutting plate, the first groove is impressed into the surface by plastically deforming the structure.

A method for producing a surface that has a surface structure of predetermined geometry, that is suitable for application of material by thermal spraying and is in the form of a geometrically determined groove structure, the method comprising:

• forming at least a first groove having a final cross-sectional contour in a surface of a structure by sequentially contacting locations on the surface of the structure with at least a first cutting tool and a second cutting tool of a cutting plate, the cutting plate is a single unitary piece of material comprising at least the first cutting tool and the second cutting tool, the first cutting tool is a first projection, the second cutting tool is a second projection, the first projection is separate from the second projection, the first projection is spaced from the second projection, said contacting locations on the surface of the structure with the first cutting tool causing material to be removed from the structure, the first groove having a first cross-sectional contour at each said location after said contacting the structure with the first cutting tool, said contacting the structure with the second cutting tool causing material to be removed from the structure, the first groove having a second cross-sectional contour at each said location after said contacting the structure with the second cutting tool,
• the final cross-sectional contour comprising a portion of the first cross-sectional contour and a portion of the second cross-sectional contour
• wherein the surface is cylindrical and wherein said method comprises forming with the cutting plate an intermediate groove in the surface between portions of the first groove so that undercut-like material deformations in the first groove are generated.

A method for producing a surface that has a surface structure of predetermined geometry, that is suitable for application of material by thermal spraying and is in the form of a geometrically determined groove structure, the method comprising:

• introducing a first groove into a surface of a structure by:
• removing material from the structure by contacting the structure with at least a first cutting tool, and
• plastically deforming part of the structure by applying blunt force by contacting the surface of the structure with at least a first displacement structure,
• wherein the surface is cylindrical and wherein said method further comprises forming an intermediate groove in the cylindrical surface between portions of the first groove so that undercut-like material deformations in the first groove are generated.

A method for producing a surface that has a surface structure of predetermined geometry, that is suitable for application of material by thermal spraying and is in the form of a geometrically determined groove structure, the method comprising:

• introducing a first groove into a surface of a structure by:
• removing material from the structure by contacting the structure with at least a first cutting tool, and
• plastically deforming part of the structure by applying blunt force by contacting the surface of the structure with at least a first displacement structure,
• the first cutting tool and the first displacement structure are both on a first cutting plate,
• the first cutting plate further comprises a third portion,
• the third portion of the first cutting plate is a cutting tool,
• the first cutting tool is spaced from the third portion of the first cutting plate by a first pitch,
• the method comprises rotating at least one of the surface and the first cutting plate such that the surface rotates, relative to the first cutting tool of the first cutting plate and the first displacement structure of the first cutting plate, about a first axis while moving at least one of (1) the surface and (2) the first cutting plate along the first axis, the moving resulting in changing the relative position along the surface relative to the first cutting plate, and
• the rate of changing the relative position along the first axis of the surface relative to the first cutting plate is equal to a product of:
• (1) the rate of rotating the surface relative to the first cutting tool and the first displacement structure about the first axis times (2) the first pitch.

A method for producing a surface that has a surface structure of predetermined geometry, that is suitable for application of material by thermal spraying and is in the form of a geometrically determined groove structure, the method comprising:

• introducing with a first portion of a cutting plate a first groove into a surface of a structure,
• processing at least a portion of the first groove with at least a second portion of the cutting plate, and
• forming with the cutting plate an intermediate groove in the surface between portions of the first groove so that undercut-like material deformations in the first groove are generated,
• one of the first portion and the second portion of the cutting plate a cutting tool that causes material to be removed from the structure,
• the other of the first portion and the second portion of the cutting plate a displacement structure that plastically deforms part of the structure by applying blunt force.

A method for producing a surface that has a surface structure of predetermined geometry, that is suitable for application of material by thermal spraying and is in the form of a geometrically determined groove structure, the method comprising:

• introducing with a first portion of a cutting plate a first groove into a cylindrical surface of a structure, the first groove extends at least one revolution about an axis of the cylindrical surface, and
• subsequently processing at least a portion of the first groove with at least a second portion of the cutting plate,
• one of the first portion and the second portion of the cutting plate a cutting tool that causes material to be removed from the structure,
• the other of the first portion and the second portion of the cutting plate a displacement structure that plastically deforms part of the structure by applying blunt force.

A method for producing a surface that has a surface structure of predetermined geometry, that is suitable for application of material by thermal spraying and is in the form of a geometrically determined groove structure, the method comprising:

• introducing with a first portion of a cutting plate a first groove into a surface of a structure,
• processing at least a portion of the first groove with at least a second portion of the cutting plate,
• rotating at least one of the surface and the cutting plate such that the surface rotates, relative to the first portion of the cutting plate and the second portion of the cutting plate, about a first axis while moving at least one of (1) the surface and (2) the cutting plate along the first axis, the moving resulting in changing the relative position along the surface relative to the cutting plate,
• the first portion of the cutting plate is a cutting tool that causes material to be removed from the structure,
• the second portion of the cutting plate is a displacement structure that plastically deforms part of the structure by applying blunt force,
• the cutting plate further comprising a third portion, the third portion of the cutting plate is a cutting tool,
• the first portion of the cutting plate is spaced from the third portion of the cutting plate by a first pitch,
• the rate of changing the relative position along the first axis of the surface relative to the cutting plate is equal to a product of:
• (1) the rate of rotating the surface relative to the cutting plate about the first axis times (2) the first pitch.

A method for roughening a surface of a structure, the method comprising:

• rotating at least one of a structure and a cutting plate such that the surface of the structure rotates, relative to the first portion of the cutting plate and the second portion of the cutting plate, about a first axis, the cutting plate a single unitary piece of material comprising at least a first portion and a second portion,
• moving at least one of the structure and the cutting plate, such that the surface of the structure moves, relative to the cutting plate, along the first axis, the moving resulting in changing the relative position of the surface relative to the cutting plate along the first axis,
• said rotating and said moving resulting in:
• at least the first portion and the second portion of the cutting plate forming at least a first groove in the surface of the structure, and
• the structure contacting a displacement feature to plastically deform part of the structure, the displacement feature a portion of the cutting plate, the plastically deforming the structure causing a change in the shape of the first groove.