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Coupling evaluation for material removal and thermal control on precision milling machine tools

《机械工程前沿（英文）》 2022年 第17卷 第1期   页码 12-12 doi: 10.1007/s11465-021-0668-9

摘要： Machine tools are one of the most representative machining systems in manufacturing. The energy consumption of machine tools has been a research hotspot and frontier for green low-carbon manufacturing. However, previous research merely regarded the material removal (MR) energy as useful energy consumption and ignored the useful energy consumed by thermal control (TC) for maintaining internal thermal stability and machining accuracy. In pursuit of energy-efficient, high-precision machining, more attention should be paid to the energy consumption of TC and the coupling relationship between MR and TC. Hence, the cutting energy efficiency model considering the coupling relationship is established based on the law of conservation of energy. An index of energy consumption ratio of TC is proposed to characterize its effect on total energy usage. Furthermore, the heat characteristics are analyzed, which can be adopted to represent machining accuracy. Experimental study indicates that TC is the main energy-consuming process of the precision milling machine tool, which overwhelms the energy consumption of MR. The forced cooling mode of TC results in a 7% reduction in cutting energy efficiency. Regression analysis shows that heat dissipation positively contributes 54.1% to machining accuracy, whereas heat generation negatively contributes 45.9%. This paper reveals the coupling effect of MR and TC on energy efficiency and machining accuracy. It can provide a foundation for energy-efficient, high-precision machining of machine tools.

关键词： machine tools     cutting energy efficiency     thermal stability     machining accuracy     coupling evaluation    

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Preparation and characterization of a novel microorganism embedding material for simultaneous nitrification

Ming Zeng, Ping Li, Nan Wu, Xiaofang Li, Chang Wang

《环境科学与工程前沿（英文）》 2017年 第11卷 第6期 doi: 10.1007/s11783-017-0961-3

摘要： A novel microorganism embedding material was prepared to enhance the biological nitrogen removal through simultaneous nitrification and denitrification. Polyvinyl alcohol (PVA), sodium alginate (SA) and cyclodextrin (CD) were used to compose gel bead with embedded activated sludge. The effects of temperature, CD addition and concentrations of PVA and SA on nitrogen removal were evaluated. Results show that the gel bead with CD addition at 30°C contributed to the highest nitrogen removal efficiency and nitrogen removal rate of 85.4% and 2.08 mg·(L·h)?1, respectively. Meanwhile, negligible NO3? and NO2? were observed, proving the occurrence of simultaneous nitrification and denitrification. The High-Throughput Sequencing confirms that the microbial community mainly contained Comamonadaceae in the proportion of 61.3%. Overall, CD increased gel bead’s porosity and resulted in the high specific endogenous respiration rate and high nitrogen removal efficiency, which is a favorable additional agent to the traditional embedding material.

关键词： Immobilization technology     Nitrogen removal     Cyclodextrin     Microbial community     Wastewater treatment    

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Effect of the degree of template removal from mesoporous silicate materials on their adsorption of heavy

Farouq TWAIQ,M.S. NASSER,Sagheer A. ONAIZI

《化学科学与工程前沿（英文）》 2014年 第8卷 第4期   页码 488-497 doi: 10.1007/s11705-014-1459-1

摘要： The key aim of this study is to evaluate the adsorption of heavy oil from aqueous solutions with different oil contents over mesoporous silicate materials having different surfactant template contents. The mesoporous silicate materials have been synthesized from tetraethylorthosilicate as a silica precursor and cetyltrimethylammonium bromide as a template using the sol-gel technique. Four samples were prepared by (1) totally removing the template using the calcination process, (2) partially removing the template via ethanol extraction, (3) partially removing the template via water extraction, and (4) keeping the template as synthesized, respectively. These four samples have been characterized using X-ray diffraction, nitrogen adsorption, thermal gravimetric analysis and Fourier transformed infrared. The effect of the degree of template removal of these mesoporous materials for the oil removal has been investigated. The oil removal is inversely proportional to the surfactant content in the mesoporous material, being highest for the calcined sample but lowest for the as-synthesized sample. The kinetic of oil adsorption over the calcined material has been also studied and the data obtained fit well a second-order model.

关键词： heavy oil     mesoporous silicate material     kinetics     template removal     adsorption    

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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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Mercury removal from aqueous solution using petal-like MoS2

Ragini Pirarath, Palani Shivashanmugam, Asad Syed, Abdallah M. Elgorban, Sambandam Anandan, Muthupandian Ashokkumar

《环境科学与工程前沿（英文）》 2021年 第15卷 第1期 doi: 10.1007/s11783-020-1307-0

摘要： Abstract • Synthesized few-layered MoS2 nanosheets via surfactant-assisted hydrothermal method. • Synthesized MoS2 nanosheets show petal-like morphology. • Adsorbent showed 93% of mercury removal efficiency. • The adsorption of mercury is attributed to negative zeta potential (-21.8 mV). Recently, different nanomaterial-based adsorbents have received greater attention for the removal of environmental pollutants, specifically heavy metals from aqueous media. In this work, we synthesized few-layered MoS2 nanosheets via a surfactant-assisted hydrothermal method and utilized them as an efficient adsorbent for the removal of mercury from aqueous media. The synthesized MoS2 nanosheets showed petal-like morphology as confirmed by scanning electron microscope and high-resolution transmission electron microscopic analysis. The average thickness of the nanosheets is found to be about 57 nm. Possessing high stability and negative zeta potential makes this material suitable for efficient adsorption of mercury from aqueous media. The adsorption efficiency of the adsorbent was investigated as a function of pH, contact time and adsorbent dose. The kinetics of adsorption and reusability potential of the adsorbent were also performed. A pseudo-second-order kinetics for mercury adsorption was observed. As prepared MoS2 nanosheets showed 93% mercury removal efficiency, whereas regenerated adsorbent showed 91% and 79% removal efficiency in the respective 2nd and 3rd cycles. The adsorption capacity of the adsorbent was found to be 289 mg/g at room temperature.

关键词： Anionic surfactant     2D material     MoS2 nanosheets     Mercury removal     Adsorption capacity    

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Liquid metal material genome: Initiation of a new research track towards discovery of advanced energy

Lei WANG, Jing LIU

《能源前沿（英文）》 2013年 第7卷 第3期   页码 317-332 doi: 10.1007/s11708-013-0271-9

摘要： As the basis of modern industry, the roles materials play are becoming increasingly vital in this day and age. With many superior physical properties over conventional fluids, the low melting point liquid metal material, especially room-temperature liquid metal, is recently found to be uniquely useful in a wide variety of emerging areas from energy, electronics to medical sciences. However, with the coming enormous utilization of such materials, serious issues also arise which urgently need to be addressed. A biggest concern to impede the large scale application of room-temperature liquid metal technologies is that there is currently a strong shortage of the materials and species available to meet the tough requirements such as cost, melting point, electrical and thermal conductivity, etc. Inspired by the Material Genome Initiative as issued in 2011 by the United States of America, a more specific and focused project initiative was proposed in this paper—the liquid metal material genome aimed to discover advanced new functional alloys with low melting point so as to fulfill various increasing needs. The basic schemes and road map for this new research program, which is expected to have a worldwide significance, were outlined. The theoretical strategies and experimental methods in the research and development of liquid metal material genome were introduced. Particularly, the calculation of phase diagram (CALPHAD) approach as a highly effective way for material design was discussed. Further, the first-principles (FP) calculation was suggested to combine with the statistical thermodynamics to calculate the thermodynamic functions so as to enrich the CALPHAD database of liquid metals. When the experimental data are too scarce to perform a regular treatment, the combination of FP calculation, cluster variation method (CVM) or molecular dynamics (MD), and CALPHAD, referred to as the mixed FP-CVM-CALPHAD method can be a promising way to solve the problem. Except for the theoretical strategies, several parallel processing experimental methods were also analyzed, which can help improve the efficiency of finding new liquid metal materials and reducing the cost. The liquid metal material genome proposal as initiated in this paper will accelerate the process of finding and utilization of new functional materials.

关键词： liquid metal material genome     energy material     material discovery     advanced material     room-temperature liquid alloy     thermodynamics     phase diagram    

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Robust topology optimization of multi-material lattice structures under material and load uncertainties

Yu-Chin CHAN, Kohei SHINTANI, Wei CHEN

《机械工程前沿（英文）》 2019年 第14卷 第2期   页码 141-152 doi: 10.1007/s11465-019-0531-4

摘要： Enabled by advancements in multi-material additive manufacturing, lightweight lattice structures consisting of networks of periodic unit cells have gained popularity due to their extraordinary performance and wide array of functions. This work proposes a density-based robust topology optimization method for meso- or macro-scale multi-material lattice structures under any combination of material and load uncertainties. The method utilizes a new generalized material interpolation scheme for an arbitrary number of materials, and employs univariate dimension reduction and Gauss-type quadrature to quantify and propagate uncertainty. By formulating the objective function as a weighted sum of the mean and standard deviation of compliance, the tradeoff between optimality and robustness can be studied and controlled. Examples of a cantilever beam lattice structure under various material and load uncertainty cases exhibit the efficiency and flexibility of the approach. The accuracy of univariate dimension reduction is validated by comparing the results to the Monte Carlo approach.

关键词： robust topology optimization     lattice structures     multi-material     material uncertainty     load uncertainty     univariate dimension reduction    

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Ultrasonic assisted EDM: Effect of the workpiece vibration in the machining characteristics of FW4 Welded Metal

Mohammadreza SHABGARD, Hamed KAKOLVAND, Mirsadegh SEYEDZAVVAR, Ramin Mohammadpour SHOTORBANI

《机械工程前沿（英文）》 2011年 第6卷 第4期   页码 419-428 doi: 10.1007/s11465-011-0246-7

摘要：

This paper presents the results of experimental studies carried out to conduct a comprehensive investigation on the influence of ultrasonic vibration of workpiece on the characteristics of Electrical Discharge Machining (EDM) process of FW4 Welding Metal in comparison with the conventional EDM process. The studied process characteristics included the material removal rate (MRR), tool wear ratio (TWR), and surface roughness (Ra and Rmax) of the workpiece after the EDM and ultrasonic assisted EDM (US-EDM) processes. The experiments performed under the designed full factorial procedure and the considered EDM input parameters included pulse on-time and pulse current. The experimental results show that in short pulse on-times, material removal rate in the US-EDM process is approximately quadruple than that of the EDM process. On the contrary, in the long pulse on-times, ultrasonic vibration of work??piece leads to the reduction in the MRR. On the other hand, in short pulse on-times, the TWR in the US-EDM process is lower than that of in the EDM process, and this condition reverses with increase in the pulse on-time. Furthermore, the surface roughness of the workpiece machined by EDM process is slightly lower than that of applied to the US-EDM process.

关键词： electrical discharge machining (EDM)     material removal rate (MRR)     tool wear ratio (TWR)     surface roughness    

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Experimental study on high-efficiency polishing for potassium dihydrogen phosphate (KDP) crystal by using two-phase air–water fluid

Ziyuan LIU, Hang GAO, Dongming GUO

《机械工程前沿（英文）》 2020年 第15卷 第2期   页码 294-302 doi: 10.1007/s11465-019-0576-4

摘要： A high-efficiency polishing approach using two-phase air–water fluid (TAWF) is proposed to avoid surface contamination and solve the inefficiency of previous water-dissolution polishing techniques for potassium dihydrogen phosphate (KDP) crystal. In the proposed method, controllable deliquescence is implemented without any chemical impurity. The product of deliquescence is then removed by a polishing pad to achieve surface planarization. The mechanism underlying TAWF polishing is analyzed, a special device is built to polish the KDP crystal, and the effect of relative humidity (RH) on polishing performance is studied. The relationship between key parameters of polishing and surface planarization is also investigated. Results show that the polishing performance is improved with increasing RH. However, precisely controlling the RH is extremely difficult during TAWF polishing. Controllable deliquescence can easily be disrupted once the RH fluctuates, which therefore needs to be restricted to a low level to avoid its influence on deliquescence rate. The material removal of TAWF polishing is mainly attributed to the synergistic effect of deliquescence and the polishing pad. Excessive polishing pressure and revolution rate remarkably reduce the life of the polishing pad and the surface quality of the KDP crystal. TAWF polishing using IC-1000 and TEC-168S increase the machining efficiency by 150%, and a smooth surface with a root mean square surface roughness of 5.5 nm is obtained.

关键词： potassium dihydrogen phosphate (KDP) crystal     controllable deliquescence     two-phase air–water fluid     high-efficiency polishing     material removal    

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工程材料研究中科学问题的思考

于翘

《中国工程科学》 1999年 第1卷 第3期   页码 1-4

摘要：

在不少场合下，航天用工程材料处在极端条件下工作，这就对材料提出许多特殊的要求，虽然国内外有一定的研究积累，但对更精确的模型和符合特定材料的损伤的状态方程，有待深一步研究。如高级弹头再入时气动加热和粒子云侵蚀以及两者耦合效应引起弹头防护材料增大后退量的问题；空中垃圾和微流星的高速碰撞对航天器的威胁；特别是核爆和激光武器对材料的损伤和破坏，实质上是辐射引起的热击波层裂破坏，这些都属于超高速碰撞对材料的响应问题。天线罩材料、吸波材料、红外隐身材料、电磁屏蔽材料都是具有不同波长电磁波的电磁功能材料，它们对固体介质的穿透、吸收、反射等会产生响应，不同的电磁功能材料，其宏观性能的物理参量不同，但有几个参量是通用的，如介电常数、磁导率和损耗角正切，搞清这些参量与材料微观结构的关系，可以为材料设计和材料创新提供科学依据。

关键词： 天线罩材料     吸波材料     红外隐身材料     电磁兼容材料    

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A novel approach to minimizing material loss for computer numerical control flank-regrinding of worn

《机械工程前沿（英文）》 2023年 第18卷 第3期 doi: 10.1007/s11465-023-0757-z

摘要： Flanks of end mills are prone to wear in a long machining process. Regrinding is widely used in workshops to restore the flank to an original-like state. However, the traditional method involves material waste by trial and error and dramatically decreases the potential regrinding. Moreover, over-cut would happen to the flutes of worn cutters in the regrinding processes because of improper wheel path. This study presented a new approach to planning the wheel path for regrinding worn end mills to minimize material loss and recover the over-cut. In planning, a scaling method was developed to determine the maximum size of the new cutter according to the similarity of cutter shapes before and after regrinding. Then, the wheel path is first generated by envelope theory to regrind the worn area with a four-axis computer numerical control grinder according to the new size of cutters. Moreover, a second regrinding strategy is applied to recover the flute shape over-cut in the first grinding. Finally, the proposed method is verified by an experiment. Results showed that the proposed approach could save 25% of cutter material compared with the traditional method and ensure at least three regrinding times. This work effectively provides a general regrinding solution for the worn flank with maximum material-saving and regrinding period.

关键词： flank-regrinding     worn end mill     wheel position and orientation     material loss     over-cut    

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Research progress in removal of trace carbon dioxide from closed spaces

ZHANG Yatao, FAN Lihai, ZHANG Lin, CHEN Huanlin

《化学科学与工程前沿（英文）》 2007年 第1卷 第3期   页码 310-316 doi: 10.1007/s11705-007-0057-x

摘要： In this paper, the removal of trace carbon dioxide from closed spaces through membrane process and biotransformation are introduced in detail. These methods include the microalgae photobioreactor, membrane microalgae photobioreactor, supported liquid membrane, membrane gas-liquid contactor, hydrogel membrane, and enzyme membrane bioreactor. The advantages and disadvantages of these methods are compared. It is found that higher CO removal efficiency can be obtained in biotransformation and membrane process. However, a large volume and high energy consumption are needed in biotransformation, while the low permeability and stability must be solved in the membrane process.

关键词： removal efficiency     consumption     removal     CO removal     membrane microalgae    

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A MATLAB code for the material-field series-expansion topology optimization method

《机械工程前沿（英文）》 2021年 第16卷 第3期   页码 607-622 doi: 10.1007/s11465-021-0637-3

摘要： This paper presents a MATLAB implementation of the material-field series-expansion (MFSE) topo-logy optimization method. The MFSE method uses a bounded material field with specified spatial correlation to represent the structural topology. With the series-expansion method for bounded fields, this material field is described with the characteristic base functions and the corresponding coefficients. Compared with the conventional density-based method, the MFSE method decouples the topological description and the finite element discretization, and greatly reduces the number of design variables after dimensionality reduction. Other features of this method include inherent control on structural topological complexity, crisp structural boundary description, mesh independence, and being free from the checkerboard pattern. With the focus on the implementation of the MFSE method, the present MATLAB code uses the maximum stiffness optimization problems solved with a gradient-based optimizer as examples. The MATLAB code consists of three parts, namely, the main program and two subroutines (one for aggregating the optimization constraints and the other about the method of moving asymptotes optimizer). The implementation of the code and its extensions to topology optimization problems with multiple load cases and passive elements are discussed in detail. The code is intended for researchers who are interested in this method and want to get started with it quickly. It can also be used as a basis for handling complex engineering optimization problems by combining the MFSE topology optimization method with non-gradient optimization algorithms without sensitivity information because only a few design variables are required to describe relatively complex structural topology and smooth structural boundaries using the MFSE method.

关键词： MATLAB implementation     topology optimization     material-field series-expansion method     bounded material field     dimensionality reduction    

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A multiscale material model for heterogeneous liquid droplets in solid soft composites

《结构与土木工程前沿（英文）》 2021年 第15卷 第5期   页码 1292-1299 doi: 10.1007/s11709-021-0771-3

摘要： Liquid droplets in solid soft composites have been attracting increasing attention in biological applications. In contrary with conventional composites, which are made of solid elastic inclusions, available material models for composites including liquid droplets are for highly idealized configurations and do not include all material real parameters. They are also all deterministic and do not address the uncertainties arising from droplet radius, volume fraction, dispersion and agglomeration. This research revisits the available models for liquid droplets in solid soft composites and presents a multiscale computational material model to determine their elastic moduli, considering nearly all relevant uncertainties and heterogeneities at different length scales. The effects of surface tension at droplets interface, their volume fraction, size, size polydispersity and agglomeration on elastic modulus, are considered. Different micromechanical material models are incorporated into the presented computational framework. The results clearly indicate both softening and stiffening effects of liquid droplets and show that the model can precisely predict the effective properties of liquid droplets in solid soft composites.

关键词： liquid in solid     soft composite     computational modeling     multiscale model     heterogeneity    

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Influence of soft rock-fill material as dam embankment with central bituminous concrete membrane

Peter TSCHERNUTTER

《结构与土木工程前沿（英文）》 2011年 第5卷 第1期   页码 63-70 doi: 10.1007/s11709-010-0016-3

摘要： This paper demonstrates the difficulties in determining the relevant material parameters for a valuation of the deformation behavior of the up- and downstream dam shell by means of an embankment dam of medium height. Laboratory as well as field tests on solid rock-fill material were performed before the beginning of construction. During the construction the properties of the available rock-fill changed from solid to soft materials. This gave rise to the necessity of adjusting the dam design of the downstream dam shoulder. Several times higher dam settlements as well as significant differential settlements between the up- and downstream dam shell were observed during construction and operation. Apart from this situation, the dam has been operated for nearly 20 years and the behavior of the water barrier has been very good.

关键词： embankment dam     bituminous concrete membrane     rock-fill material properties     deformation behavior    

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标题 作者 时间 类型 操作

Coupling evaluation for material removal and thermal control on precision milling machine tools

期刊论文

Preparation and characterization of a novel microorganism embedding material for simultaneous nitrification

Ming Zeng, Ping Li, Nan Wu, Xiaofang Li, Chang Wang

期刊论文

Effect of the degree of template removal from mesoporous silicate materials on their adsorption of heavy

Farouq TWAIQ,M.S. NASSER,Sagheer A. ONAIZI

期刊论文

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

期刊论文

Mercury removal from aqueous solution using petal-like MoS2

Ragini Pirarath, Palani Shivashanmugam, Asad Syed, Abdallah M. Elgorban, Sambandam Anandan, Muthupandian Ashokkumar

期刊论文

Liquid metal material genome: Initiation of a new research track towards discovery of advanced energy

Lei WANG, Jing LIU

期刊论文

Robust topology optimization of multi-material lattice structures under material and load uncertainties

Yu-Chin CHAN, Kohei SHINTANI, Wei CHEN

期刊论文

Ultrasonic assisted EDM: Effect of the workpiece vibration in the machining characteristics of FW4 Welded Metal

Mohammadreza SHABGARD, Hamed KAKOLVAND, Mirsadegh SEYEDZAVVAR, Ramin Mohammadpour SHOTORBANI

期刊论文

Experimental study on high-efficiency polishing for potassium dihydrogen phosphate (KDP) crystal by using two-phase air–water fluid

Ziyuan LIU, Hang GAO, Dongming GUO

期刊论文

工程材料研究中科学问题的思考

于翘

期刊论文

A novel approach to minimizing material loss for computer numerical control flank-regrinding of worn

期刊论文

Research progress in removal of trace carbon dioxide from closed spaces

ZHANG Yatao, FAN Lihai, ZHANG Lin, CHEN Huanlin

期刊论文

A MATLAB code for the material-field series-expansion topology optimization method

期刊论文

A multiscale material model for heterogeneous liquid droplets in solid soft composites

期刊论文

Influence of soft rock-fill material as dam embankment with central bituminous concrete membrane

Peter TSCHERNUTTER

期刊论文