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Machinability of ultrasonic vibration-assisted micro-grinding in biological bone using nanolubricant

《机械工程前沿（英文）》 2023年 第18卷 第1期 doi: 10.1007/s11465-022-0717-z

摘要： Bone grinding is an essential and vital procedure in most surgical operations. Currently, the insufficient cooling capacity of dry grinding, poor visibility of drip irrigation surgery area, and large grinding force leading to high grinding temperature are the technical bottlenecks of micro-grinding. A new micro-grinding process called ultrasonic vibration-assisted nanoparticle jet mist cooling (U-NJMC) is innovatively proposed to solve the technical problem. It combines the advantages of ultrasonic vibration (UV) and nanoparticle jet mist cooling (NJMC). Notwithstanding, the combined effect of multi parameter collaborative of U-NJMC on cooling has not been investigated. The grinding force, friction coefficient, specific grinding energy, and grinding temperature under dry, drip irrigation, UV, minimum quantity lubrication (MQL), NJMC, and U-NJMC micro-grinding were compared and analyzed. Results showed that the minimum normal grinding force and tangential grinding force of U-NJMC micro-grinding were 1.39 and 0.32 N, which were 75.1% and 82.9% less than those in dry grinding, respectively. The minimum friction coefficient and specific grinding energy were achieved using U-NJMC. Compared with dry, drip, UV, MQL, and NJMC grinding, the friction coefficient of U-NJMC was decreased by 31.3%, 17.0%, 19.0%, 9.8%, and 12.5%, respectively, and the specific grinding energy was decreased by 83.0%, 72.7%, 77.8%, 52.3%, and 64.7%, respectively. Compared with UV or NJMC alone, the grinding temperature of U-NJMC was decreased by 33.5% and 10.0%, respectively. These results showed that U-NJMC provides a novel approach for clinical surgical micro-grinding of biological bone.

关键词： micro-grinding     biological bone     ultrasonic vibration (UV)     nanoparticle jet mist cooling (NJMC)     grinding force     grinding temperature    

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Vibration characteristics and machining performance of a novel perforated ultrasonic vibration platformin the grinding of particulate-reinforced titanium matrix composites

《机械工程前沿（英文）》 2023年 第18卷 第1期 doi: 10.1007/s11465-022-0730-2

摘要： Ultrasonic vibration-assisted grinding (UVAG) is an advanced hybrid process for the precision machining of difficult-to-cut materials. The resonator is a critical part of the UVAG system. Its performance considerably influences the vibration amplitude and resonant frequency. In this work, a novel perforated ultrasonic vibration platform resonator was developed for UVAG. The holes were evenly arranged at the top and side surfaces of the vibration platform to improve the vibration characteristics. A modified apparent elasticity method (AEM) was proposed to reveal the influence of holes on the vibration mode. The performance of the vibration platform was evaluated by the vibration tests and UVAG experiments of particulate-reinforced titanium matrix composites. Results indicate that the reasonable distribution of holes helps improve the resonant frequency and vibration mode. The modified AEM, the finite element method, and the vibration tests show a high degree of consistency for developing the perforated ultrasonic vibration platform with a maximum frequency error of 3%. The employment of ultrasonic vibration reduces the grinding force by 36% at most, thereby decreasing the machined surface defects, such as voids, cracks, and burnout.

关键词： ultrasonic vibration-assisted grinding     perforated ultrasonic vibration platform     vibration characteristics     apparent elasticity method     grinding force     surface integrity    

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Hole quality in longitudinal–torsional coupled ultrasonic vibration assisted drilling of carbon fiber

Guofeng MA, Renke KANG, Zhigang DONG, Sen YIN, Yan BAO, Dongming GUO

《机械工程前沿（英文）》 2020年 第15卷 第4期   页码 538-546 doi: 10.1007/s11465-020-0598-y

摘要： Carbon fiber reinforced plastic (CFRP) composites are extremely attractive in the manufacturing of structural and functional components in the aircraft manufacturing field due to their outstanding properties, such as good fatigue resistance, high specific stiffness/strength, and good shock absorption. However, because of their inherent anisotropy, low interlamination strength, and abrasive characteristics, CFRP composites are considered difficult-to-cut materials and are prone to generating serious hole defects, such as delamination, tearing, and burrs. The advanced longitudinal–torsional coupled ultrasonic vibration assisted drilling (LTC-UAD) method has a potential application for drilling CFRP composites. At present, LTC-UAD is mainly adopted for drilling metal materials and rarely for CFRP. Therefore, this study analyzes the kinematic characteristics and the influence of feed rate on the drilling performance of LTC-UAD. Experimental results indicate that LTC-UAD can reduce the thrust force by 39% compared to conventional drilling. Furthermore, LTC-UAD can decrease the delamination and burr factors and improve the surface quality of the hole wall. Thus, LTC-UAD is an applicable process method for drilling components made with CFRP composites.

关键词： longitudinal–torsional coupled     ultrasonically drilling     CFRP     thrust force     hole quality    

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

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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Design of ultrasonic elliptical vibration cutting system for tungsten heavy alloy

《机械工程前沿（英文）》 2022年 第17卷 第4期 doi: 10.1007/s11465-022-0715-1

摘要： Nanoscale surface roughness of tungsten heavy alloy components is required in the nuclear industry and precision instruments. In this study, a high-performance ultrasonic elliptical vibration cutting (UEVC) system is developed to solve the precision machining problem of tungsten heavy alloy. A new design method of stepped bending vibration horn based on Timoshenko’s theory is first proposed, and its design process is greatly simplified. The arrangement and working principle of piezoelectric transducers on the ultrasonic vibrator using the fifth resonant mode of bending are analyzed to realize the dual-bending vibration modes. A cutting tool is installed at the end of the ultrasonic vibration unit to output the ultrasonic elliptical vibration locus, which is verified by finite element method. The vibration unit can display different three-degree-of-freedom (3-DOF) UEVC characteristics by adjusting the corresponding position of the unit and workpiece. A dual-channel ultrasonic power supply is developed to excite the ultrasonic vibration unit, which makes the UEVC system present the resonant frequency of 41 kHz and the maximum amplitude of 14.2 μm. Different microtopography and surface roughness are obtained by the cutting experiments of tungsten heavy alloy hemispherical workpiece with the UEVC system, which validates the proposed design’s technical capability and provides optimization basis for further improving the machining quality of the curved surface components of tungsten heavy alloy.

关键词： tungsten heavy alloy     ultrasonic elliptical vibration cutting     Timoshenko’s theory     resonant mode of bending     finite element method    

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Recent advances in ultrasonic-assisted machining for the fabrication of micro/nano-textured surfaces

Shaolin XU,Tsunemoto KURIYAGAWA,Keita SHIMADA,Masayoshi MIZUTANI

《机械工程前沿（英文）》 2017年 第12卷 第1期   页码 33-45 doi: 10.1007/s11465-017-0422-5

摘要：

In this paper, the state of art of ultrasonic-assisted machining technologies used for fabrication of micro/nano-textured surfaces is reviewed. Diamond machining is the most widely used method in industry for manufacturing precision parts. For fabrication of fine structures on surfaces, conventional diamond machining methods are competitive by considering the precision of structures, but have limitations at machinable structures and machining efficiency, which have been proved to be partly solved by the integration of ultrasonic vibration motion. In this paper, existing ultrasonic-assisted machining methods for fabricating fine surface structures are reviewed and classified, and a rotary ultrasonic texturing (RUT) technology is mainly introduced by presenting the construction of vibration spindles, the texturing principles, and the applications of textured surfaces. Some new ideas and experimental results are presented. Finally, the challenges in using the RUT method to fabricate micro/nano-textured surfaces are discussed with respect to texturing strategies, machinable structures, and tool wear.

关键词： ultrasonic-assisted machining     textured surface     micro/nano-structures     functional performance    

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Radial electromagnetic type unbalance vibration self-recovery regulation system for high-end grinding

《机械工程前沿（英文）》 2023年 第18卷 第3期 doi: 10.1007/s11465-023-0763-1

摘要： Modern rotating machines, which are represented by high-end grinding machines, have developed toward high precision, intelligence, and high durability in recent years. As the core components of grinding machine spindles, grinding wheels greatly affect the vibration level during operation. The unbalance vibration self-recovery regulation (UVSRR) system is proposed to suppress the vibration of grinding wheels during workpiece processing, eliminating or minimizing the imbalance. First, technical principles and the system composition are introduced. Second, the balancing actuator in the UVSRR system is analyzed in detail. The advanced nature of the improved structure is presented through structure introduction and advantage analysis. The performance of the balancing actuator is mutually verified by the theoretical calculation of torque and software simulation. Results show that the self-locking torque satisfies the actual demand, and the driving torque is increased by 1.73 times compared with the traditional structure. Finally, the engineering application value of the UVSRR system is verified by laboratory performance comparison and actual factory application. The balancing speed and effect of the UVSRR system are better than those of an international mainstream product and, the quality of the workpieces machined in the factory improved by 40%.

关键词： UVSRR system     radial electromagnetic type     vibration suppression     performance simulation     engineering application    

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Detection of solder bump defects on a flip chip using vibration analysis

Junchao LIU, Tielin SHI, Qi XIA, Guanglan LIAO

《机械工程前沿（英文）》 2012年 第7卷 第1期   页码 29-37 doi: 10.1007/s11465-012-0314-7

摘要：

Flip chips are widely used in microelectronics packaging owing to the high demand of integration in IC fabrication. Solder bump defects on flip chips are difficult to detect, because the solder bumps are obscured by the chip and substrate. In this paper a nondestructive detection method combining ultrasonic excitation with vibration analysis is presented for detecting missing solder bumps, which is a typical defect in flip chip packaging. The flip chip analytical model is revised by considering the influence of spring mass on mechanical energy of the system. This revised model is then applied to estimate the flip chip resonance frequencies. We use an integrated signal generator and power amplifier together with an air-coupled ultrasonic transducer to excite the flip chips. The vibrations are measured by a laser scanning vibrometer to detect the resonance frequencies. A sensitivity coefficient is proposed to select the sensitive resonance frequency order for defect detection. Finite element simulation is also implemented for further investigation. The results of analytical computation, experiment, and simulation prove the efficacy of the revised flip chip analytical model and verify the effectiveness of this detection method. Therefore, it may provide a guide for the improvement and innovation of the flip chip on-line inspection systems.

关键词： flip chip     defect detection     ultrasonic excitation     vibration analysis    

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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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Ultrasonic linear motor using the L-B mode Langevin transducer with an exponential horn

SHI Shengjun, CHEN Weishan, LIU Junkao, ZHAO Xuetao

《机械工程前沿（英文）》 2008年 第3卷 第2期   页码 212-217 doi: 10.1007/s11465-008-0026-1

摘要： An ultrasonic linear motor is proposed and fabricated by using the longitudinal and bending vibration double mode bolt-clamped Langevin type transducer to meet high power and speed requirements in the aerospace and semiconductor ind

关键词： longitudinal     vibration     bolt-clamped     semiconductor     ultrasonic    

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Ultrasound-assisted co-precipitation synthesis of mesoporous Co3O4–CeO2 composite oxides for highly selective

《化学科学与工程前沿（英文）》 2022年 第16卷 第8期   页码 1211-1223 doi: 10.1007/s11705-022-2145-3

摘要： The one-step highly selective oxidation of cyclohexane into cyclohexanone and cyclohexanol as the essential intermediates of nylon-6 and nylon-66 is considerably challenging. Therefore, an efficient and low-cost catalyst must be urgently developed to improve the efficiency of this process. In this study, a Co3O4–CeO2 composite oxide catalyst was successfully prepared through ultrasound-assisted co-precipitation. This catalyst exhibited a higher selectivity to KA-oil, which was benefited from the synergistic effects between Co3+/Co2+ and Ce4+/Ce3+ redox pairs, than bulk CeO2 and/or Co3O4. Under the optimum reaction conditions, 89.6% selectivity to KA-oil with a cyclohexane conversion of 5.8% was achieved over Co3O4–CeO2. Its catalytic performance remained unchanged after five runs. Using the synergistic effects between the redox pairs of different transition metals, this study provides a feasible strategy to design high-performance catalysts for the selective oxidation of alkanes.

关键词： Co3O4–CeO2 composite oxides     cyclohexanone     cyclohexanol     ultrasonic-assisted co-precipitation     selective oxidation     solvent-free    

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Piezocatalytic performance of FeO−BiMoO catalyst for dye degradation

《化学科学与工程前沿（英文）》 2023年 第17卷 第6期   页码 716-725 doi: 10.1007/s11705-022-2265-9

摘要： A Fe2O3−Bi2MoO6 heterojunction was synthesized via a hydrothermal method. Scanning electron microscopy, transmission electron microscopy, energy-dispersive X-ray, powder X-ray diffraction, Fourier transform infrared spectroscopy and ultra-violet−visible near-infrared spectrometry were performed to measure the structures, morphologies and optical properties of the as-prepared samples. The various factors that affected the piezocatalytic property of composite catalyst were studied. The highest rhodamine B degradation rate of 96.6% was attained on the 3% Fe2O3−Bi2MoO6 composite catalyst under 60 min of ultrasonic vibration. The good piezocatalytic activity was ascribed to the formation of a hierarchical flower-shaped microsphere structure and the heterostructure between Fe2O3 and Bi2MoO6, which effectively separated the ultrasound-induced electron–hole pairs and suppressed their recombination. Furthermore, a potential piezoelectric catalytic dye degradation mechanism of the Fe2O3−Bi2MoO6 catalyst was proposed based on the band potential and quenching effect of radical scavengers. The results demonstrated the potential of using Fe2O3−Bi2MoO6 nanocomposites in piezocatalytic applications.

关键词： piezocatalysis     Fe2O3−Bi2MoO6     dye decomposition     ultrasonic vibration    

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Subsurface damage pattern and formation mechanism of monocrystalline -GaO in grinding process

《机械工程前沿（英文）》 2022年 第17卷 第2期 doi: 10.1007/s11465-022-0677-3

摘要： Monocrystalline beta-phase gallium oxide (β-Ga2O3) is a promising ultrawide bandgap semiconductor material. However, the deformation mechanism in ultraprecision machining has not yet been revealed. The aim of this study is to investigate the damage pattern and formation mechanism of monocrystalline β-Ga2O3 in different grinding processes. Transmission electron microscopy was used to observe the subsurface damage in rough, fine, and ultrafine grinding processes. Nanocrystals and stacking faults existed in all three processes, dislocations and twins were observed in the rough and fine grinding processes, cracks were also observed in the rough grinding process, and amorphous phase were only present in the ultrafine grinding process. The subsurface damage thickness of the samples decreased with the reduction in the grit radius and the grit depth of cut. Subsurface damage models for grinding process were established on the basis of the grinding principle, revealing the mechanism of the mechanical effect of grits on the damage pattern. The formation of nanocrystals and amorphous phase was related to the grinding conditions and material characteristics. It is important to investigate the ultraprecision grinding process of monocrystalline β-Ga2O3. The results in this work are supposed to provide guidance for the damage control of monocrystalline β-Ga2O3 grinding process.

关键词： monocrystalline beta-phase gallium oxide     grinding process     subsurface damage     nanocrystals     amorphous phase    

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Simulation and analysis of grinding wheel based on Gaussian mixture model

Yulun CHI, Haolin LI

《机械工程前沿（英文）》 2012年 第7卷 第4期   页码 427-432 doi: 10.1007/s11465-012-0350-3

摘要：

This article presents an application of numerical simulation technique for the generation and analysis of the grinding wheel surface topographies. The ZETA 20 imaging and metrology microscope is employed to measure the surface topographies. The Gaussian mixture model (GMM) is used to transform the measured non-Gaussian field to Gaussian fields, and the simulated topographies are generated. Some numerical examples are used to illustrate the viability of the method. It shows that the simulated grinding wheel topographies are similar with the measured and can be effective used to study the abrasive grains and grinding mechanism.

关键词： grinding wheel     3D topographies measurement     Gaussian mixture model     simulation    

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Investigation on drilling-grinding of CFRP

Yanming QUAN, Wenwang ZHONG

《机械工程前沿（英文）》 2009年 第4卷 第1期   页码 60-63 doi: 10.1007/s11465-009-0008-y

摘要： It is difficult to machine polymer matrix composites reinforced by carbon fibre, and the hole-making process is the most necessary machining process for composite plate products. Conventional drills have a very short life in the drilling of this kind of composites and the quality of the hole is very poor. In this paper, the cemented or plated diamond core tools are tested to make holes in carbon fibre/epoxy composite plates. The effects of machining parameters, cooling and chip removal on the tool life, and the hole quality are investigated. Results indicate that the material removal mechanism of the two kinds of diamond tools is not like the cutting effect of the conventional solid twist drilling but similar to that of grinding. Satisfactory effects in making holes in the composites are obtained— quite acceptable machined hole quality, low costs, and long wear-resistant endurance.

关键词： composites     drilling-grinding     cemented/plated diamond     tool life     machined quality    

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标题 作者 时间 类型 操作

Machinability of ultrasonic vibration-assisted micro-grinding in biological bone using nanolubricant

期刊论文

Vibration characteristics and machining performance of a novel perforated ultrasonic vibration platformin the grinding of particulate-reinforced titanium matrix composites

期刊论文

Hole quality in longitudinal–torsional coupled ultrasonic vibration assisted drilling of carbon fiber

Guofeng MA, Renke KANG, Zhigang DONG, Sen YIN, Yan BAO, Dongming GUO

期刊论文

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

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

期刊论文

Design of ultrasonic elliptical vibration cutting system for tungsten heavy alloy

期刊论文

Recent advances in ultrasonic-assisted machining for the fabrication of micro/nano-textured surfaces

Shaolin XU,Tsunemoto KURIYAGAWA,Keita SHIMADA,Masayoshi MIZUTANI

期刊论文

Radial electromagnetic type unbalance vibration self-recovery regulation system for high-end grinding

期刊论文

Detection of solder bump defects on a flip chip using vibration analysis

Junchao LIU, Tielin SHI, Qi XIA, Guanglan LIAO

期刊论文

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

期刊论文

Ultrasonic linear motor using the L-B mode Langevin transducer with an exponential horn

SHI Shengjun, CHEN Weishan, LIU Junkao, ZHAO Xuetao

期刊论文

Ultrasound-assisted co-precipitation synthesis of mesoporous Co3O4–CeO2 composite oxides for highly selective

期刊论文

Piezocatalytic performance of FeO−BiMoO catalyst for dye degradation

期刊论文

Subsurface damage pattern and formation mechanism of monocrystalline -GaO in grinding process

期刊论文

Simulation and analysis of grinding wheel based on Gaussian mixture model

Yulun CHI, Haolin LI

期刊论文

Investigation on drilling-grinding of CFRP

Yanming QUAN, Wenwang ZHONG

期刊论文