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Cryogenic minimum quantity lubrication machining: from mechanism to application

《机械工程前沿（英文）》 2021年第16卷第4期页码 649-697 doi: 10.1007/s11465-021-0654-2

摘要： Cutting fluid plays a cooling–lubrication role in the cutting of metal materials. However, the substantial usage of cutting fluid in traditional flood machining seriously pollutes the environment and threatens the health of workers. Environmental machining technologies, such as dry cutting, minimum quantity lubrication (MQL), and cryogenic cooling technology, have been used as substitute for flood machining. However, the insufficient cooling capacity of MQL with normal-temperature compressed gas and the lack of lubricating performance of cryogenic cooling technology limit their industrial application. The technical bottleneck of mechanical–thermal damage of difficult-to-cut materials in aerospace and other fields can be solved by combining cryogenic medium and MQL. The latest progress of cryogenic minimum quantity lubrication (CMQL) technology is reviewed in this paper, and the key scientific issues in the research achievements of CMQL are clarified. First, the application forms and process characteristics of CMQL devices in turning, milling, and grinding are systematically summarized from traditional settings to innovative design. Second, the cooling–lubrication mechanism of CMQL and its influence mechanism on material hardness, cutting force, tool wear, and workpiece surface quality in cutting are extensively revealed. The effects of CMQL are systematically analyzed based on its mechanism and application form. Results show that the application effect of CMQL is better than that of cryogenic technology or MQL alone. Finally, the prospect, which provides basis and support for engineering application and development of CMQL technology, is introduced considering the limitations of CMQL.

关键词： cryogenic minimum quantity lubrication (CMQL) cryogenic medium processing mode device application mechanism application effect

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Nanoparticle-enhanced coolants in machining: mechanism, application, and prospects

《机械工程前沿（英文）》 2023年第18卷第4期 doi: 10.1007/s11465-023-0769-8

摘要： Nanoparticle-enhanced coolants (NPECs) are increasingly used in minimum quantity lubrication (MQL) machining as a green lubricant to replace conventional cutting fluids to meet the urgent need for carbon emissions and achieve sustainable manufacturing. However, the thermophysical properties of NPEC during processing remain unclear, making it difficult to provide precise guidance and selection principles for industrial applications. Therefore, this paper reviews the action mechanism, processing properties, and future development directions of NPEC. First, the laws of influence of nano-enhanced phases and base fluids on the processing performance are revealed, and the dispersion stabilization mechanism of NPEC in the preparation process is elaborated. Then, the unique molecular structure and physical properties of NPECs are combined to elucidate their unique mechanisms of heat transfer, penetration, and anti-friction effects. Furthermore, the effect of NPECs is investigated on the basis of their excellent lubricating and cooling properties by comprehensively and quantitatively evaluating the material removal characteristics during machining in turning, milling, and grinding applications. Results showed that turning of Ti‒6Al‒4V with multi-walled carbon nanotube NPECs with a volume fraction of 0.2% resulted in a 34% reduction in tool wear, an average decrease in cutting force of 28%, and a 7% decrease in surface roughness Ra, compared with the conventional flood process. Finally, research gaps and future directions for further applications of NPECs in the industry are presented.

关键词： nanoparticle-enhanced coolant minimum quantity lubrication biolubricant thermophysical properties turning milling grinding

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A review of low-temperature plasma-assisted machining: from mechanism to application

《机械工程前沿（英文）》 2023年第18卷第1期 doi: 10.1007/s11465-022-0734-y

摘要： Materials with high hardness, strength or plasticity have been widely used in the fields of aviation, aerospace, and military, among others. However, the poor machinability of these materials leads to large cutting forces, high cutting temperatures, serious tool wear, and chip adhesion, which affect machining quality. Low-temperature plasma contains a variety of active particles and can effectively adjust material properties, including hardness, strength, ductility, and wettability, significantly improving material machinability. In this paper, we first discuss the mechanisms and applications of low-temperature plasma-assisted machining. After introducing the characteristics, classifications, and action mechanisms of the low-temperature plasma, we describe the effects of the low-temperature plasma on different machining processes of various difficult-to-cut materials. The low-temperature plasma can be classified as hot plasma and cold plasma according to the different equilibrium states. Hot plasma improves material machinability via the thermal softening effect induced by the high temperature, whereas the main mechanisms of the cold plasma can be summarized as chemical reactions to reduce material hardness, the hydrophilization effect to improve surface wettability, and the Rehbinder effect to promote fracture. In addition, hybrid machining methods combining the merits of the low-temperature plasma and other energy fields like ultrasonic vibration, liquid nitrogen, and minimum quantity lubrication are also described and analyzed. Finally, the promising development trends of low-temperature plasma-assisted machining are presented, which include more precise control of the heat-affected zone in hot plasma-assisted machining, cold plasma-assisted polishing of metal materials, and further investigations on the reaction mechanisms between the cold plasma and other materials.

关键词： low-temperature plasma difficult-to-cut material machinability hydrophilization effect Rehbinder effect

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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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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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Theoretical and experimental analysis on super precision grinding of monocrystal silicon

GUO Xiaoguang, GUO Dongming, KANG Renke, JIN Zhuji

《机械工程前沿（英文）》 2007年第2卷第2期页码 137-143 doi: 10.1007/s11465-007-0023-9

摘要： Through investigating the diamond-silicon grinding system, the grinding mechanism, including chip removal and subsurface damage, is discussed with the aid of the molecular dynamics (MD) approach and grinding experiments. Based on MD simulation, nanometric-grinding mechanism is analyzed from the viewpoint of instantaneous distribution of atoms, grinding force, and the potential energy between atoms and the profile of the groove. The simulation results show that some silicon atoms are deformed and piled up in front and on two sides of the abrasive surface because of the extrusion and cutting. When the energy in silicon lattice reaches its maximum value, the bonds of silicon atoms are broken and the material is removed. With the advancement of the abrasive, the silicon lattice under the abrasive surface is fractured, and then the amorphous layers are formed and propagated, which causes the subsurface damage. At the same time, some amorphous atoms are reconstructed and the degenerating layer of the machined surface is formed. Besides, the recovery of elatstic deformation occurs in the machined surface of the workpiece. In addition, the grinding experiment and profile detection with the aid of the measurment for 3D profiling are performed to verify the simulation results. The good agreement in the profile of the groove between the experimental value and the simulating value shows that MD simulation is very effective and reliable, and successful to fulfill the investigation on nanometric machining mechanism.

关键词： machining mechanism recovery advancement mechanism subsurface

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Tool wear mechanisms in the machining of Nickel based super-alloys: A review

Waseem AKHTAR,Jianfei SUN,Pengfei SUN,Wuyi CHEN,Zawar SALEEM

《机械工程前沿（英文）》 2014年第9卷第2期页码 106-119 doi: 10.1007/s11465-014-0301-2

摘要：

Nickel based super-alloys are widely employed in aircraft engines and gas turbines due to their high temperature strength, corrosion resistance and, excellent thermal fatigue properties. Conversely, these alloys are very difficult to machine and cause rapid wear of the cutting tool, frequent tool changes are thus required resulting in low economy of the machining process. This study provides a detailed review of the tool wear mechanism in the machining of nickel based super-alloys. Typical tool wear mechanisms found by different researchers are analyzed in order to find out the most prevalent wear mechanism affecting the tool life. The review of existing works has revealed interesting findings about the tool wear mechanisms in the machining of these alloys. Adhesion wear is found to be the main phenomenon leading to the cutting tool wear in this study.

关键词： tool wear nickel based super-alloy wear mechanism

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A novel six-legged walking machine tool for

Jimu LIU, Yuan TIAN, Feng GAO

《机械工程前沿（英文）》 2020年第15卷第3期页码 351-364 doi: 10.1007/s11465-020-0594-2

摘要： The manufacture and maintenance of large parts in ships, trains, aircrafts, and so on create an increasing demand for mobile machine tools to perform operations. However, few mobile robots can accommodate the complex environment of industrial plants while performing machining tasks. This study proposes a novel six-legged walking machine tool consisting of a legged mobile robot and a portable parallel kinematic machine tool. The kinematic model of the entire system is presented, and the workspace of different components, including a leg, the body, and the head, is analyzed. A hierarchical motion planning scheme is proposed to take advantage of the large workspace of the legged mobile platform and the high precision of the parallel machine tool. The repeatability of the head motion, body motion, and walking distance is evaluated through experiments, which is 0.11, 1.0, and 3.4 mm, respectively. Finally, an application scenario is shown in which the walking machine tool steps successfully over a 250 mm-high obstacle and drills a hole in an aluminum plate. The experiments prove the rationality of the hierarchical motion planning scheme and demonstrate the extensive potential of the walking machine tool for operations on large parts.

关键词： legged robot parallel mechanism mobile machine tool in-situ machining

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Equipment–process–strategy integration for sustainable machining: a review

《机械工程前沿（英文）》 2023年第18卷第3期 doi: 10.1007/s11465-023-0752-4

摘要： Although the manufacturing industry has improved the quality of processing, optimization and upgrading must be performed to meet the requirements of global sustainable development. Sustainable production is considered to be a favorable strategy for achieving machining upgrades characterized by high quality, high efficiency, energy savings, and emission reduction. Sustainable production has aroused widespread interest, but only a few scholars have studied the sustainability of machining from multiple dimensions. The sustainability of machining must be investigated multidimensionally and accurately. Thus, this study explores the sustainability of machining from the aspects of equipment, process, and strategy. In particular, the equipment, process, and strategy of sustainable machining are systematically analyzed and integrated into a research framework. Then, this study analyzes sustainable machining-oriented machining equipment from the aspects of machine tools, cutting tools, and materials such as cutting fluid. Machining processes are explored as important links of sustainable machining from the aspects of dry cutting, microlubrication, microcutting, low-temperature cutting, and multidirectional cutting. The strategies for sustainable machining are also analyzed from the aspects of energy-saving control, machining simulation, and process optimization of machine tools. Finally, opportunities and challenges, including policies and regulations toward sustainable machining, are discussed. This study is expected to offer prospects for sustainable machining development and strategies for implementing sustainable machining.

关键词： sustainable machining equipment process strategy manufacturing

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Energy saving design of the machining unit of hobbing machine tool with integrated optimization

《机械工程前沿（英文）》 2022年第17卷第3期 doi: 10.1007/s11465-022-0694-2

摘要： The machining unit of hobbing machine tool accounts for a large portion of the energy consumption during the operating phase. The optimization design is a practical means of energy saving and can reduce energy consumption essentially. However, this issue has rarely been discussed in depth in previous research. A comprehensive function of energy consumption of the machining unit is built to address this problem. Surrogate models are established by using effective fitting methods. An integrated optimization model for reducing tool displacement and energy consumption is developed on the basis of the energy consumption function and surrogate models, and the parameters of the motor and structure are considered simultaneously. Results show that the energy consumption and tool displacement of the machining unit are reduced, indicating that energy saving is achieved and the machining accuracy is guaranteed. The influence of optimization variables on the objectives is analyzed to inform the design.

关键词： energy saving design energy consumption machining unit integrated optimization machine tool

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Fixturing technology and system for thin-walled parts machining: a review

《机械工程前沿（英文）》 2022年第17卷第4期 doi: 10.1007/s11465-022-0711-5

摘要： During the overall processing of thin-walled parts (TWPs), the guaranteed capability of the machining process and quality is determined by fixtures. Therefore, reliable fixtures suitable for the structure and machining process of TWP are essential. In this review, the key role of fixtures in the manufacturing system is initially discussed. The main problems in machining and workholding due to the characteristics of TWP are then analyzed in detail. Afterward, the definition of TWP fixtures is reinterpreted from narrow and broad perspectives. Fixture functions corresponding to the issues of machining and workholding are then clearly stated. Fixture categories are classified systematically according to previous research achievements, and the operation mode, functional characteristics, and structure of each fixture are comprehensively described. The function and execution mode of TWP fixtures are then systematically summarized and analyzed, and the functions of various TWP fixtures are evaluated. Some directions for future research on TWP fixtures technology are also proposed. The main purpose of this review is to provide some reference and guidance for scholars to examine TWP fixtures.

关键词： thin-walled part (TWP) fixture machining fixture categories fixture function

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Recent advances in micro- and nano-machining technologies

Shang GAO, Han HUANG

《机械工程前沿（英文）》 2017年第12卷第1期页码 18-32 doi: 10.1007/s11465-017-0410-9

摘要：

Device miniaturization is an emerging advanced technology in the 21st century. The miniaturization of devices in different fields requires production of micro- and nano-scale components. The features of these components range from the sub-micron to a few hundred microns with high tolerance to many engineering materials. These fields mainly include optics, electronics, medicine, bio-technology, communications, and avionics. This paper reviewed the recent advances in micro- and nano-machining technologies, including micro-cutting, micro-electrical-discharge machining, laser micro-machining, and focused ion beam machining. The four machining technologies were also compared in terms of machining efficiency, workpiece materials being machined, minimum feature size, maximum aspect ratio, and surface finish.

关键词： micro machining cutting electro discharge machining (EDM) laser machining focused ion beam (FIB)

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Simulation of abrasive flow machining process for 2D and 3D mixture models

Rupalika DASH,Kalipada MAITY

《机械工程前沿（英文）》 2015年第10卷第4期页码 424-432 doi: 10.1007/s11465-015-0366-6

摘要：

Improvement of surface finish and material removal has been quite a challenge in a finishing operation such as abrasive flow machining (AFM). Factors that affect the surface finish and material removal are media viscosity, extrusion pressure, piston velocity, and particle size in abrasive flow machining process. Performing experiments for all the parameters and accurately obtaining an optimized parameter in a short time are difficult to accomplish because the operation requires a precise finish. Computational fluid dynamics (CFD) simulation was employed to accurately determine optimum parameters. In the current work, a 2D model was designed, and the flow analysis, force calculation, and material removal prediction were performed and compared with the available experimental data. Another 3D model for a swaging die finishing using AFM was simulated at different viscosities of the media to study the effects on the controlling parameters. A CFD simulation was performed by using commercially available ANSYS FLUENT. Two phases were considered for the flow analysis, and multiphase mixture model was taken into account. The fluid was considered to be a Newtonian fluid and the flow laminar with no wall slip.

关键词： abrasive flow machining (AFM) computational fluid dynamics (CFD) modeling mixture model

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Research progress on ultra-precision machining technologies for soft-brittle crystal materials

Hang GAO,Xu WANG,Dongming GUO,Yuchuan CHEN

《机械工程前沿（英文）》 2017年第12卷第1期页码 77-88 doi: 10.1007/s11465-017-0411-8

摘要：

Soft-brittle crystal materials are widely used in many fields, especially optics and microelectronics. However, these materials are difficult to machine through traditional machining methods because of their brittle, soft, and anisotropic nature. In this article, the characteristics and machining difficulties of soft-brittle and crystals are presented. Moreover, the latest research progress of novel machining technologies and their applications for soft-brittle crystals are introduced by using some representative materials (e.g., potassium dihydrogen phosphate (KDP), cadmium zinc telluride (CZT)) as examples. This article reviews the research progress of soft-brittle crystals processing.

关键词： brittle soft functional crystal ultra-precision machining

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Effects of inclination angles of disc cutter on machining quality of Nomex honeycomb core in ultrasonic

Yidan WANG, Renke KANG, Yan QIN, Qian MENG, Zhigang DONG

《机械工程前沿（英文）》 2021年第16卷第2期页码 285-297 doi: 10.1007/s11465-021-0631-9

摘要： Ultrasonic cutting with a disc cutter is an advanced machining method for the high-quality processing of Nomex honeycomb core. The machining quality is influenced by ultrasonic cutting parameters, as well as tool orientations, which are determined by the multi-axis machining requirements and the angle control of the cutting system. However, in existing research, the effect of the disc cutter orientation on the machining quality has not been studied in depth, and practical guidance for the use of disc cutters is lacking. In this work, the inclined ultrasonic cutting process with a disc cutter was analyzed, and cutting experiments with different inclination angles were conducted. The theoretical residual height models of the honeycomb core, as a result of the lead and tilt angles, were established and verified with the results obtained by a linear laser displacement sensor. Research shows that the residual height of the honeycomb core, as a result of the tilt angle, is much larger than that as a result of the lead angle. Furthermore, the tearing of the cell wall on the machined surface was observed, and the effects of the ultrasonic vibration, lead angle, and tilt angle on the tear rate and tear length of the cell wall were studied. Experimental results revealed that ultrasonic vibration can effectively decrease the tearing of the cell wall and improve the machining quality. Changes in the tilt angle have less effect than changes in the lead angle on the tearing of the cell wall. The determination of inclination angles should consider the actual processing requirements for the residual height and the machining quality of the cell wall. This study investigates the influence of the inclination angles of a disc cutter on the machining quality of Nomex honeycomb core in ultrasonic cutting and provides guidelines for machining.

关键词： Nomex honeycomb core disc cutter inclined ultrasonic cutting machining quality