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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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Self-generation of machining precision and its realization in lapping of super precision solid balls

ZHANG Bopeng

《机械工程前沿（英文）》 2008年第3卷第3期页码 348-353 doi: 10.1007/s11465-008-0065-7

摘要： This paper presents the principle of self-generation of machining precision by explaining its basic concept and five necessary conditions for forming a system with self-organization capability. A self-generation system is a kind of system with self-organization capability. The self-generation of machining precision for solid balls with super precision is emphatically explained. From the viewpoint of self-organization, there are three types of systems including system 1 with the self-regulation capability, 2 with the self-determination capability of goals, and 3 with the self-organization capability. Although they are all closed loop control systems, they have different constructions and functions. Necessary conditions for achieving self-generation of machining precision are given. Establishment of the system for machining solid balls with super precision is discussed. Self-generation of machining precision for solid balls with super precision on the basis of the capability of self-removal of errors is presented. Self-generation includes the ability of self-removal of errors for solid balls, convergence of self-removal of errors, self-generation of precision, and self-generating system for the given.

关键词： self-generation necessary self-regulation capability viewpoint Necessary

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Review on the progress of ultra-precision machining technologies

Julong YUAN, Binghai LYU, Wei HANG, Qianfa DENG

《机械工程前沿（英文）》 2017年第12卷第2期页码 158-180 doi: 10.1007/s11465-017-0455-9

摘要：

Ultra-precision machining technologies are the essential methods, to obtain the highest form accuracy and surface quality. As more research findings are published, such technologies now involve complicated systems engineering and been widely used in the production of components in various aerospace, national defense, optics, mechanics, electronics, and other high-tech applications. The conception, applications and history of ultra-precision machining are introduced in this article, and the developments of ultra-precision machining technologies, especially ultra-precision grinding, ultra-precision cutting and polishing are also reviewed. The current state and problems of this field in China are analyzed. Finally, the development trends of this field and the coping strategies employed in China to keep up with the trends are discussed.

关键词： ultra-precision grinding ultra-precision cutting ultra-precision polishing research status in China development tendency

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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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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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Micro-optical fabrication by ultraprecision diamond machining and precision molding

Hui LI, Likai LI, Neil J. NAPLES, Jeffrey W. ROBLEE, Allen Y. YI

《机械工程前沿（英文）》 2017年第12卷第2期页码 181-192 doi: 10.1007/s11465-017-0444-z

摘要：

Ultraprecision diamond machining and high volume molding for affordable high precision high performance optical elements are becoming a viable process in optical industry for low cost high quality microoptical component manufacturing. In this process, first high precision microoptical molds are fabricated using ultraprecision single point diamond machining followed by high volume production methods such as compression or injection molding. In the last two decades, there have been steady improvements in ultraprecision machine design and performance, particularly with the introduction of both slow tool and fast tool servo. Today optical molds, including freeform surfaces and microlens arrays, are routinely diamond machined to final finish without post machining polishing. For consumers, compression molding or injection molding provide efficient and high quality optics at extremely low cost. In this paper, first ultraprecision machine design and machining processes such as slow tool and fast too servo are described then both compression molding and injection molding of polymer optics are discussed. To implement precision optical manufacturing by molding, numerical modeling can be included in the future as a critical part of the manufacturing process to ensure high product quality.

关键词： ultraprecision machining slow tool servo fast tool servo compression molding injection molding microlens arrays optical fabrication

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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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高端光学元件超精密加工技术与装备发展研究

蒋庄德, 李常胜, 孙林, 段端志, 康城玮, 陈杉杉, 林启敬, 杨树明

《中国工程科学》 2023年第25卷第1期页码 131-141 doi: 10.15302/J-SSCAE-2023.07.003

摘要：

高端光学元件是决定高端装备性能水平的核心零件，研究高端光学元件超精密加工技术与装备发展，对于实施制造强国战略、满足高端装备产业需求具有积极意义。本文剖析了光学元件超精密加工方法与装备、高性能基础部件、超精密光学加工中的测量方法与装备等的发展情况，凝练了精度与尺寸极端化、形状与性能一体化、加工工艺复合化、加工与检测一体化、装备与工艺智能化等发展趋势。通过广泛的行业调研和研讨，从需求、目标、产品、关键技术、应用示范、支撑保障等层次着手，形成了面向2035 年我国高端光学元件超精密制造技术路线图。针对性提出了优化创新体系设置、组织优势资源成立技术联盟，加大资源保障力度、布局基础研究和技术攻关计划，加强人才培育、构建梯队并扩大队伍规模，筑牢产业发展基础、培育龙头企业和专精特新“小巨人”企业等发展建议，以期促进高端光学元件加工产业提升与高质量发展。

关键词：光学元件；精密制造；超精密机床；超精密加工；光学加工

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高性能零件的性能与几何参数一体化精密加工方法与技术

郭东明

《中国工程科学》 2011年第13卷第10期页码 47-57

摘要：

随着高端装备和产品的不断发展，对装备和产品制造的性能要求也越来越多和越来越高，涌现出一大批高性能指标要求的关键零部件，其加工已由以往的单纯几何形状和尺寸精度要求，跃升为以性能要求为主、性能与几何参数一体化的精密加工要求。这些高性能零件多呈精密复杂曲面、超高精度，以及材料超硬、超脆、超黏等难加工特征，其性能受几何、材料等多因素耦合作用，采用传统工艺进行精密加工制造十分困难，存在废品率高、加工效率低，特别是性能指标难以保证等难题。从高端制造装备业的需求出发，提出并阐明了高性能零件的特点、分类以及数字化可控去除加工方式的内涵，在此基础上指出了四类高性能零件精密加工所涉及的关键问题，并着重介绍了这些问题的研究现状、存在的难点和可行的解决方案，为面向高性能要求的性能与几何参数一体化的加工理论、方法和工艺技术体系的建立提供参考，以解决高性能零件的精密制造难题。

关键词：高性能性能与几何参数一体化精密加工难加工材料复杂曲面

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Identification of thermal error in a feed system based on multi-class LS-SVM

Chao JIN, Bo WU, Youmin HU, Yao CHENG

《机械工程前沿（英文）》 2012年第7卷第1期页码 47-54 doi: 10.1007/s11465-012-0307-6

摘要：

Research of thermal characteristics has been a key issue in the development of high-speed feed system. The thermal positioning error of a ball-screw is one of the most important objects to consider for high-accuracy and high-speed machine tools. The research work undertaken herein ultimately aims at the development of a comprehensive thermal error identification model with high accuracy and robust. Using multi-class least squares support vector machines (LS-SVM), the thermal positioning error of the feed system is identified with the variance and mean square value of the temperatures of supporting bearings and screw-nut as feature vector. A series of experiments were carried out on a self-made quasi high-speed feed system experimental bench HUST-FS-001 to verify the identification capacity of the presented method. The results show that the recommended model can be used to predict the thermal error of a feed system with good accuracy, which is better than the ordinary BP and RBF neural network. The work described in this paper lays a solid foundation of thermal error prediction and compensation in a feed system.

关键词： least squares support vector machine (LS-SVM) feed system thermal error precision 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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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