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Microstructure investigation of dynamic recrystallization in hard machining: From thermodynamic irreversibility

Binxun LI, Xinzhi ZHANG, Song ZHANG

《机械工程前沿（英文）》 2021年 第16卷 第2期   页码 315-330 doi: 10.1007/s11465-020-0612-4

摘要： The drastically changed thermal, mechanical, and chemical energies within the machined surface layer during hard machining tend to initiate microstructural alteration. In this paper, attention is paid to the introduction of thermodynamic potential to unravel the mechanism of microstructure evolution. First, the thermodynamic potential-based model expressed by the Helmholtz free energy was proposed for predicting the microstructure changes of serrated chip and the machined surface layer. Second, the proposed model was implemented into a validated finite element simulation model for cutting operation as a user-defined subroutine. In addition, the predicted irreversible thermodynamic state change in the deformation zones associated with grain size, which was reduced to less than 1 m from the initial size of 1.5 m on the machined surface, was provided for an in-depth explanation. The good consistency between the simulated results and experimental data validated the efficacy of the developed model. This research helps to provide further insight into the microstructure alteration during metal cutting.

关键词： thermodynamic irreversibility     Helmholtz free energy     microstructure evolution     dynamic recrystallization     hard milling    

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Energy field-assisted high-speed dry milling green machining technology for difficult-to-machine metal

《机械工程前沿（英文）》 2023年 第18卷 第2期 doi: 10.1007/s11465-022-0744-9

摘要： Energy field-assisted machining technology has the potential to overcome the limitations of machining difficult-to-machine metal materials, such as poor machinability, low cutting efficiency, and high energy consumption. High-speed dry milling has emerged as a typical green processing technology due to its high processing efficiency and avoidance of cutting fluids. However, the lack of necessary cooling and lubrication in high-speed dry milling makes it difficult to meet the continuous milling requirements for difficult-to-machine metal materials. The introduction of advanced energy-field-assisted green processing technology can improve the machinability of such metallic materials and achieve efficient precision manufacturing, making it a focus of academic and industrial research. In this review, the characteristics and limitations of high-speed dry milling of difficult-to-machine metal materials, including titanium alloys, nickel-based alloys, and high-strength steel, are systematically explored. The laser energy field, ultrasonic energy field, and cryogenic minimum quantity lubrication energy fields are introduced. By analyzing the effects of changing the energy field and cutting parameters on tool wear, chip morphology, cutting force, temperature, and surface quality of the workpiece during milling, the superiority of energy-field-assisted milling of difficult-to-machine metal materials is demonstrated. Finally, the shortcomings and technical challenges of energy-field-assisted milling are summarized in detail, providing feasible ideas for realizing multi-energy field collaborative green machining of difficult-to-machine metal materials in the future.

关键词： difficult-to-machine metal material     green machining     high-speed dry milling     laser energy field-assisted milling     ultrasonic energy field-assisted milling     cryogenic minimum quantity lubrication energy field-assisted milling    

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Analysis of load and adaptability of disc cutters during shield tunneling in soft–hard varied strata

《结构与土木工程前沿（英文）》 2023年 第17卷 第4期   页码 533-545 doi: 10.1007/s11709-023-0946-1

摘要： The disc cutters of shield machines exhibit unsatisfactory adaptability and performance during the soft–hard varied strata tunneling process. To analyze the rotation state, cutting performance, and adaptability of disc cutters during shield tunneling in soft–hard varied strata, the Holmquist Johnson Cook and Federal Highway Administration constitutive models are introduced to numerically simulate the failure process of materials on the excavation face and to calculate the load of disc cutters. Additionally, the parameters of the models are modified based on laboratory disc cutter excavation test results. The results of numerical calculation can reflect the load level and the behavior of the disc cutters during operation. The tangential loads of the disc cutters during the cutting of four typical soft-strata excavation face models are numerically calculated, thus providing reference values for the starting torque of the disc cutters. A greater penetration is suggested for soft-strata tunneling to allow the disc cutters to rotate smoothly and continuously as well as to guarantee a better cutting effect. The disc cutters in the center of the cutterhead should be specified with a lower starting torque to prevent uneven wear, rotation stagnation, cutterhead clogging, and other adverse phenomena.

关键词： shield tunneling     disc cutter load     laboratory excavation test     numerical calculation     soft–hard varied strata    

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Advances in molecular dynamics simulation of ultra-precision machining of hard and brittle materials

Xiaoguang GUO,Qiang LI,Tao LIU,Renke KANG,Zhuji JIN,Dongming GUO

《机械工程前沿（英文）》 2017年 第12卷 第1期   页码 89-98 doi: 10.1007/s11465-017-0412-7

摘要：

Hard and brittle materials, such as silicon, SiC, and optical glasses, are widely used in aerospace, military, integrated circuit, and other fields because of their excellent physical and chemical properties. However, these materials display poor machinability because of their hard and brittle properties. Damages such as surface micro-crack and subsurface damage often occur during machining of hard and brittle materials. Ultra-precision machining is widely used in processing hard and brittle materials to obtain nanoscale machining quality. However, the theoretical mechanism underlying this method remains unclear. This paper provides a review of present research on the molecular dynamics simulation of ultra-precision machining of hard and brittle materials. The future trends in this field are also discussed.

关键词： MD simulation     ultra-precision machining     hard and brittle materials     machining mechanism     review    

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浅埋深两硬条件下特厚煤层综放开采技术

张忠温,吴吉南

《中国工程科学》 2011年 第13卷 第11期   页码 107-112

摘要：

针对平朔矿区4号煤层条件，采用理论分析方法研究了浅埋深两硬条件下4号煤层顶煤的冒放性及合理采煤方法。以提高顶煤冒放性为目标，采用数值模拟的方法进行了综放工作面参数及设备选型配套研究。实践表明，浅埋深两硬煤层条件下通过加大综放工作面长度与割煤高度，可以实现安全、高效、高回收率开采。

关键词： 浅埋深     两硬煤层     顶煤冒放性     大采高综放    

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Primary cilia in hard tissue development and diseases

《医学前沿（英文）》 2021年 第15卷 第5期   页码 657-678 doi: 10.1007/s11684-021-0829-6

摘要： Bone and teeth are hard tissues. Hard tissue diseases have a serious effect on human survival and quality of life. Primary cilia are protrusions on the surfaces of cells. As antennas, they are distributed on the membrane surfaces of almost all mammalian cell types and participate in the development of organs and the maintenance of homeostasis. Mutations in cilium-related genes result in a variety of developmental and even lethal diseases. Patients with multiple ciliary gene mutations present overt changes in the skeletal system, suggesting that primary cilia are involved in hard tissue development and reconstruction. Furthermore, primary cilia act as sensors of external stimuli and regulate bone homeostasis. Specifically, substances are trafficked through primary cilia by intraflagellar transport, which affects key signaling pathways during hard tissue development. In this review, we summarize the roles of primary cilia in long bone development and remodeling from two perspectives: primary cilia signaling and sensory mechanisms. In addition, the cilium-related diseases of hard tissue and the manifestations of mutant cilia in the skeleton and teeth are described. We believe that all the findings will help with the intervention and treatment of related hard tissue genetic diseases.

关键词： primary cilia     bone     mechanical sensing     hard tissue     cilium-related bone disease     tooth    

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Fiber-reinforced composites in milling and grinding: machining bottlenecks and advanced strategies

《机械工程前沿（英文）》 2022年 第17卷 第2期 doi: 10.1007/s11465-022-0680-8

摘要： Fiber-reinforced composites have become the preferred material in the fields of aviation and aerospace because of their high-strength performance in unit weight. The composite components are manufactured by near net-shape and only require finishing operations to achieve final dimensional and assembly tolerances. Milling and grinding arise as the preferred choices because of their precision processing. Nevertheless, given their laminated, anisotropic, and heterogeneous nature, these materials are considered difficult-to-machine. As undesirable results and challenging breakthroughs, the surface damage and integrity of these materials is a research hotspot with important engineering significance. This review summarizes an up-to-date progress of the damage formation mechanisms and suppression strategies in milling and grinding for the fiber-reinforced composites reported in the literature. First, the formation mechanisms of milling damage, including delamination, burr, and tear, are analyzed. Second, the grinding mechanisms, covering material removal mechanism, thermal mechanical behavior, surface integrity, and damage, are discussed. Third, suppression strategies are reviewed systematically from the aspects of advanced cutting tools and technologies, including ultrasonic vibration-assisted machining, cryogenic cooling, minimum quantity lubrication (MQL), and tool optimization design. Ultrasonic vibration shows the greatest advantage of restraining machining force, which can be reduced by approximately 60% compared with conventional machining. Cryogenic cooling is the most effective method to reduce temperature with a maximum reduction of approximately 60%. MQL shows its advantages in terms of reducing friction coefficient, force, temperature, and tool wear. Finally, research gaps and future exploration directions are prospected, giving researchers opportunity to deepen specific aspects and explore new area for achieving high precision surface machining of fiber-reinforced composites.

关键词： milling     grinding     fiber-reinforced composites     damage formation mechanism     delamination     material removal mechanism     surface integrity     minimum quantity lubrication    

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Crystalline mesoporous transition metal oxides: hard-templating synthesis and application in environmental

Zhen MA, Bei ZHOU, Yu REN

《环境科学与工程前沿（英文）》 2013年 第7卷 第3期   页码 341-355 doi: 10.1007/s11783-012-0472-1

摘要： Mesoporous silicas such as MCM-41 and SBA-15 possess high surface areas, ordered nanopores, and excellent thermal stability, and have been often used as catalyst supports. Although mesoporous metal oxides have lower surface areas compared to mesoporous silicas, they generally have more diversified functionalities. Mesoporous metal oxides can be synthesized via a soft-templating or hard-templating approach, and these materials have recently found some applications in environmental catalysis, such as CO oxidation, N O decomposition, and elimination of organic pollutants. In this review, we summarize the synthesis of mesoporous transition metal oxides using mesoporous silicas as hard templates, highlight the application of these materials in environmental catalysis, and furnish some prospects for future development.

关键词： mesoporous materials     silica     metal oxide     hard-templating     environmental catalysis    

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Cutting Force Model for a Small-diameter Helical Milling Cutter

LI Xiwen, YANG Shuzi, YANG Mingjin, XIE Shouyong

《机械工程前沿（英文）》 2007年 第2卷 第3期   页码 272-277 doi: 10.1007/s11465-007-0047-1

摘要： In the milling process, the major flank wear land area (two-dimensional measurement for the wear) of a small-diameter milling cutter, as wear standard, can reflect actual changes of the wear land of the cutter. By analyzing the wearing characteristics of the cutter, a cutting force model based on the major flank wear land area is established. Characteristic parameters such as pressure parameter and friction parameter are calculated by substituting tested data into their corresponding equations. The cutting force model for the helical milling cutter is validated by experiments. The computational and experimental results show that the cutting force model is almost consistent with the actual cutting conditions. Thus, the cutting force model established in the research can provide a theoretical foundation for monitoring the condition of a milling process that uses a small-diameter helical milling cutter.

关键词： computational     corresponding     helical milling     theoretical foundation     Characteristic    

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Position-varying surface roughness prediction method considering compensated acceleration in milling

《机械工程前沿（英文）》 2021年 第16卷 第4期   页码 855-867 doi: 10.1007/s11465-021-0649-z

摘要： Machined surface roughness will affect parts’ service performance. Thus, predicting it in the machining is important to avoid rejects. Surface roughness will be affected by system position dependent vibration even under constant parameter with certain toolpath processing in the finishing. Aiming at surface roughness prediction in the machining process, this paper proposes a position-varying surface roughness prediction method based on compensated acceleration by using regression analysis. To reduce the stochastic error of measuring the machined surface profile height, the surface area is repeatedly measured three times, and Pauta criterion is adopted to eliminate abnormal points. The actual vibration state at any processing position is obtained through the single-point monitoring acceleration compensation model. Seven acceleration features are extracted, and valley, which has the highest R-square proving the effectiveness of the filtering features, is selected as the input of the prediction model by mutual information coefficients. Finally, by comparing the measured and predicted surface roughness curves, they have the same trends, with the average error of 16.28% and the minimum error of 0.16%. Moreover, the prediction curve matches and agrees well with the actual surface state, which verifies the accuracy and reliability of the model.

关键词： surface roughness prediction     compensated acceleration     milling     thin-walled workpiece    

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Field and laboratory experimental studies on hard-rock tunnel excavation based on disc cutter coupled

《结构与土木工程前沿（英文）》   页码 1370-1386 doi: 10.1007/s11709-023-0947-0

摘要： The tunnel boring machine (TBM) is typically used in hard-rock tunnel excavation. Owing to the unsatisfactory adaptability of TBM to the surrounding rock, when crossing high-strength and high-wear strata, the TBM can easily cause defects, such as abnormal wear on cutters and overload damage to bearings, thus affecting the construction efficiency and cost. Therefore, high-pressure waterjet technology should be applied to assist in rock breaking for efficient TBM tunneling. In this study, the effects of water pressure, nozzle diameter, and nozzle speed on cutting are investigated via laboratory experiments of cutting hard rock using high-pressure waterjets. The penetration performance of the TBM under different water pressures is investigated via a field industrial penetration test. The results show that high-pressure waterjets are highly efficient for rock breaking and are suitable for industrial applications, as they can accommodate the advancing speed of the TBM and achieve high-efficiency rock breaking. However, during the operation of high-pressure waterjets, the ambient temperature and waterjet temperature in the tunnel increase significantly, which weakens the cooling effect of the cutterhead and decreases the construction efficiency of the TBM. Therefore, temperature control and cooling measures for high-pressure waterjets during their long-term operation must be identified. This study provides a useful reference for the design and construction of high-pressure water-jet-assisted cutterheads for breaking road headers.

关键词： tunnel boring machine     hard-rock cutting     free face     disc cutter     rock-cutting efficiency    

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Improved CO

Mahboube Ghahramaninezhad, Fatemeh Mohajer, Mahdi Niknam Shahrak

《化学科学与工程前沿（英文）》 2020年 第14卷 第3期   页码 425-435 doi: 10.1007/s11705-019-1873-5

摘要： Post-synthetic functionalization or modification has been regarded as a promising strategy to treat surfaces of adsorbents for their applications in targeted adsorption and separation processes. In this work, a novel microporous adsorbent for carbon capturing was developed via functionalization of zeolitic imidazolate framework-91 (ZIF-91) to generate a hard/hard (metal-oxygen) structure named as lithium-modified ZIF-91 (ZIF-91-OLi compound). To this purpose, the ZIF-91 compound as an intermediate product was achieved by reduction of ZIF-90 in the presence of NaBH as a good reducing agent. Afterwards, acidic hydrogen atoms in the hydroxyl groups of ZIF-91 were exchanged with lithium cations via reaction of -BuLi compound as an organo lithium agent through an appropriate procedure. In particular, the as-synthesized ZIF-91-OLi operated as an excellent electron-rich center for CO adsorption through trapping the positive carbon centers in the CO molecule. DFT calculations revealed that the presence of lithium over the surface of ZIF-91-OLi adsorbent plays an effective role in double enhancement of CO storage via creating a strong negative charge center at the oxygen atoms of the imidazolate linker as a result of the lithium/hydrogen exchange system. Finally, the selectivity of CO /N was investigated at different temperatures, revealing the ZIF-91-OLi as a selective adsorbent for industrial application.

关键词： hard/hard structure     acidic hydrogen     ZIF-91     carbon capture     ZIF-91-OLi    

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Mechanical behavior and semiempirical force model of aerospace aluminum alloy milling using nano biological

《机械工程前沿（英文）》 2023年 第18卷 第1期 doi: 10.1007/s11465-022-0720-4

摘要： Aerospace aluminum alloy is the most used structural material for rockets, aircraft, spacecraft, and space stations. The deterioration of surface integrity of dry machining and the insufficient heat transfer capacity of minimal quantity lubrication have become the bottleneck of lubrication and heat dissipation of aerospace aluminum alloy. However, the excellent thermal conductivity and tribological properties of nanofluids are expected to fill this gap. The traditional milling force models are mainly based on empirical models and finite element simulations, which are insufficient to guide industrial manufacturing. In this study, the milling force of the integral end milling cutter is deduced by force analysis of the milling cutter element and numerical simulation. The instantaneous milling force model of the integral end milling cutter is established under the condition of dry and nanofluid minimal quantity lubrication (NMQL) based on the dual mechanism of the shear effect on the rake face of the milling cutter and the plow cutting effect on the flank surface. A single factor experiment is designed to introduce NMQL and the milling feed factor into the instantaneous milling force coefficient. The average absolute errors in the prediction of milling forces for the NMQL are 13.3%, 2.3%, and 7.6% in the x-, y-, and z-direction, respectively. Compared with the milling forces obtained by dry milling, those by NMQL decrease by 21.4%, 17.7%, and 18.5% in the x-, y-, and z-direction, respectively.

关键词： milling     force     nanofluid minimum quantity lubrication     aerospace aluminum alloy     nano biological lubricant    

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A hybrid deep learning model for robust prediction of the dimensional accuracy in precision milling of

《机械工程前沿（英文）》 2022年 第17卷 第3期 doi: 10.1007/s11465-022-0688-0

摘要： The use of artificial intelligence to process sensor data and predict the dimensional accuracy of machined parts is of great interest to the manufacturing community and can facilitate the intelligent production of many key engineering components. In this study, we develop a predictive model of the dimensional accuracy for precision milling of thin-walled structural components. The aim is to classify three typical features of a structural component—squares, slots, and holes—into various categories based on their dimensional errors (i.e., “high precision,” “pass,” and “unqualified”). Two different types of classification schemes have been considered in this study: those that perform feature extraction by using the convolutional neural networks and those based on an explicit feature extraction procedure. The classification accuracy of the popular machine learning methods has been evaluated in comparison with the proposed deep learning model. Based on the experimental data collected during the milling experiments, the proposed model proved to be capable of predicting dimensional accuracy using cutting parameters (i.e., “static features”) and cutting-force data (i.e., “dynamic features”). The average classification accuracy obtained using the proposed deep learning model was 9.55% higher than the best machine learning algorithm considered in this paper. Moreover, the robustness of the hybrid model has been studied by considering the white Gaussian and coherent noises. Hence, the proposed hybrid model provides an efficient way of fusing different sources of process data and can be adopted for prediction of the machining quality in noisy environments.

关键词： precision milling     dimensional accuracy     cutting force     convolutional neural networks     coherent noise    

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Effect of magneto rheological damper on tool vibration during hard turning

P. Sam PAUL, A. S. VARADARAJAN

《机械工程前沿（英文）》 2012年 第7卷 第4期   页码 410-416 doi: 10.1007/s11465-012-0341-4

摘要：

Recently, the concept of hard turning has gained considerable attention in metal cutting as it can apparently replace the traditional process cycle of turning, heat treating, and finish grinding for assembly of hard wear resistant steel parts. The present investigation aims at developing a magneto rheological (MR) fluid damper for suppressing tool vibration and promoting better cutting performance during hard turning. The magneto rheological Fluid acts as a viscoelastic spring with non-linear vibration characteristics that are controlled by the composition of the magneto rheological fluid, the shape of the plunger and the electric parameters of the magnetizing field. Cutting experiments were conducted to arrive at a set of electrical, compositional and shape parameters that can suppress tool vibration and promote better cutting performance during turning of AISI 4340 steel of 46 HRC with minimal fluid application using hard metal insert with sculptured rake face. It was observed that the use of MR fluid damper reduces tool vibration and improves the cutting performance effectively. Also commercialization of this idea holds promise to the metal cutting industry.

关键词： tool vibration     magneto rheological damper     hard turning     surface finish     tool wear    

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标题 作者 时间 类型 操作

Microstructure investigation of dynamic recrystallization in hard machining: From thermodynamic irreversibility

Binxun LI, Xinzhi ZHANG, Song ZHANG

期刊论文

Energy field-assisted high-speed dry milling green machining technology for difficult-to-machine metal

期刊论文

Analysis of load and adaptability of disc cutters during shield tunneling in soft–hard varied strata

期刊论文

Advances in molecular dynamics simulation of ultra-precision machining of hard and brittle materials

Xiaoguang GUO,Qiang LI,Tao LIU,Renke KANG,Zhuji JIN,Dongming GUO

期刊论文

浅埋深两硬条件下特厚煤层综放开采技术

张忠温,吴吉南

期刊论文

Primary cilia in hard tissue development and diseases

期刊论文

Fiber-reinforced composites in milling and grinding: machining bottlenecks and advanced strategies

期刊论文

Crystalline mesoporous transition metal oxides: hard-templating synthesis and application in environmental

Zhen MA, Bei ZHOU, Yu REN

期刊论文

Cutting Force Model for a Small-diameter Helical Milling Cutter

LI Xiwen, YANG Shuzi, YANG Mingjin, XIE Shouyong

期刊论文

Position-varying surface roughness prediction method considering compensated acceleration in milling

期刊论文

Field and laboratory experimental studies on hard-rock tunnel excavation based on disc cutter coupled

期刊论文

Improved CO

Mahboube Ghahramaninezhad, Fatemeh Mohajer, Mahdi Niknam Shahrak

期刊论文

Mechanical behavior and semiempirical force model of aerospace aluminum alloy milling using nano biological

期刊论文

A hybrid deep learning model for robust prediction of the dimensional accuracy in precision milling of

期刊论文

Effect of magneto rheological damper on tool vibration during hard turning

P. Sam PAUL, A. S. VARADARAJAN

期刊论文