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Advances in polishing of internal structures on parts made by laser-based powder bed fusion

《机械工程前沿（英文）》 2023年第18卷第1期 doi: 10.1007/s11465-022-0724-0

摘要： The internal structures of metallic products are important in realizing functional applications. Considering the manufacturing of inner structures, laser-based powder bed fusion (L-PBF) is an attractive approach because its layering principle enables the fabrication of parts with customized interior structures. However, the inferior surface quality of L-PBF components hinders its productization progress seriously. In this article, process, basic forms, and applications relevant to L-PBF internal structures are reviewed comprehensively. The causes of poor surface quality and differences in the microstructure and property of the surface features of L-PBF inner structures are presented to provide a perspective of their surface characteristics. Various polishing technologies for L-PBF components with inner structures are presented, whereas their strengths and weaknesses are summarized along with a discussion on the challenges and prospects for improving the interior surface quality of L-PBF parts.

关键词： laser-based powder bed fusion polishing internal structures surface quality surface features post process additive manufacturing

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Review on mechanism and process of surface polishing using lasers

Arun KRISHNAN, Fengzhou FANG

《机械工程前沿（英文）》 2019年第14卷第3期页码 299-319 doi: 10.1007/s11465-019-0535-0

摘要： Laser polishing is a technology of smoothening the surface of various materials with highly intense laser beams. When these beams impact on the material surface to be polished, the surface starts to be melted due to the high temperature. The melted material is then relocated from the ‘peaks to valleys’ under the multidirectional action of surface tension. By varying the process parameters such as beam intensity, energy density, spot diameter, and feed rate, different rates of surface roughness can be achieved. High precision polishing of surfaces can be done using laser process. Currently, laser polishing has extended its applications from photonics to molds as well as bio-medical sectors. Conventional polishing techniques have many drawbacks such as less capability of polishing freeform surfaces, environmental pollution, long processing time, and health hazards for the operators. Laser polishing on the other hand eliminates all the mentioned drawbacks and comes as a promising technology that can be relied for smoothening of initial topography of the surfaces irrespective of the complexity of the surface. Majority of the researchers performed laser polishing on materials such as steel, titanium, and its alloys because of its low cost and reliability. This article gives a detailed overview of the laser polishing mechanism by explaining various process parameters briefly to get a better understanding about the entire polishing process. The advantages and applications are also explained clearly to have a good knowledge about the importance of laser polishing in the future.

关键词： laser polishing surface roughness process parameters mechanism

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面向大幅面金属增材抛光的激光扫描振镜与伺服台协同控制系统 Article

崔梦嘉, 卢立斌, 张震, 管迎春

《工程（英文）》 2021年第7卷第12期页码 1732-1740 doi: 10.1016/j.eng.2020.06.028

摘要：

为了满足高品质金属增材制造的迫切需求，本文创新地提出了一种以激光扫描振镜与精密伺服台协同控制为核心的大幅面激光精密抛光方法，以实现大幅面选区激光熔化（SLM）成形镍合金精密抛光。我们提出的协同控制系统主要包括主从式新型协同控制架构、运动矢量分解和误差合成等核心模块。研究实验结果表明，与传统步进-扫描方法相比，该协同控制系统实现了激光光斑连续运动，避免了拼接误差，加工效率提升了38.24%。由于激光扫描路径更流畅，相应能量分布更均匀，因此，大幅面抛光质量得到显著改善。本协同系统为大幅面、高精度、高效率的激光精密加工提供了重要途径，在航空航天、新能源、高端模具、医疗器械等精密制造领域具有广阔的应用前景。

关键词：协同控制激光制造拼接误差激光抛光大幅面

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静电自组装制备复合磨粒及其对铜的抛光特性研究

黄亦申,许雪峰,姚春燕,胡建德,彭伟

《中国工程科学》 2012年第14卷第10期页码 82-89

摘要：

研究苯代三聚氰胺甲醛（BGF）微球与阳离子型聚电解质聚二烯丙基二甲基氯化铵（PDADMAC）、阴离子型聚电解质聚4－苯乙烯璜酸钠（PSS）之间的吸附特性，利用静电自组装技术改变和控制BGF微球的荷电特性，制备出不同形式的PEi BGF/SiO2复合磨粒，以Zeta电位、透射电子显微镜（TEM）和热重分析（TG）等手段对复合磨粒进行了表征，并利用这些复合磨粒制备了铜片抛光用的复合磨粒抛光液。抛光试验表明，吸附在聚合物微球表面和游离于抛光液中的SiO2磨粒在抛光中均起到材料去除作用。传统单一SiO2磨粒抛光液的铜材料去除率为264 nm/min，PE0 BGF/SiO2混合磨粒抛光液的铜材料去除率为348 nm/min，PE3 BGF/SiO2复合磨粒抛光液的铜材料去除率为476 nm/min。经上述3种抛光液抛光后的铜表面，在5 μm×5 μm范围内，表面粗糙度Ra从0.166 μm分别降至3.7 nm、2.6 nm和1.5 nm，峰谷值Rpv分别小于20 nm、14 nm和10 nm，复合磨粒抛光液对铜片有良好的抛光性能。

关键词：化学机械抛光抛光液复合磨粒聚电解质铜片

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Numerical analysis of hydrodynamic process of circular-translational-moving polishing (CTMP)

ZHAI Wenjie, LIU Changxiong, LIANG Yingchun

《机械工程前沿（英文）》 2008年第3卷第4期页码 441-448 doi: 10.1007/s11465-008-0074-6

摘要： By keeping a pad moving relative to a wafer along a circular path without rotation, we developed a polishing technique called circular-translational-moving polishing (CTMP), which permits multidirectional polishing of the work piece and thus bears the advantage of isotropic polishing and a potential increase of material removal rate (MRR) on the wafer. To illuminate the mechanisms of CTMP and determine the optimum process variables in a CTMP process, a three-dimensional hydrodynamic lubrication model for CTMP with a smooth and rigid pad under a quasi-stable state is established in a polar coordinate system. The model equations are further calculated numerically by the finite difference method. The instantaneous distribution of fluid pressure is obtained, which shows that a negative pressure exists. The reason for negative pressure in CTMP and its effect on polishing is discussed. Moreover, the nominal clearance of the fluid film, roll, and pitch angles under different working conditions are obtained in terms of the applied load, moments, and polishing velocity. The obtained numerical analysis can be used as guidance for choosing operation parameters in a practical CTMP application.

关键词： numerical analysis practical CTMP circular-translational-moving polishing CTMP different

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Experimental study on high-efficiency polishing for potassium dihydrogen phosphate (KDP) crystal by using

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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激光去除与连接技术发展研究

陈俐,巩水利,何恩光

《中国工程科学》 2020年第22卷第3期页码 78-84 doi: 10.15302/J-SSCAE-2020.03.012

摘要：

随着激光技术的发展，激光去除与连接技术深刻影响着制造业技术的发展，并以柔性、高效、高质的综合优势成为不可或缺的先进制造技术。在先进制造智能化发展的时代，激光技术、数字信息技术等的融合必将推动激光去除与连接技术的应用发展与创新。本文选取工业应用最广的激光焊接、激光切割、激光打孔、激光打标4 种激光去除与连接技术，概述了激光去除与连接技术的应用现状，分析了其在支撑先进制造发展过程中存在的问题。研究表明，激光去除与连接技术的发展应注重工艺基础和装备研究一体化的研究，解决激光加工单元部件、激光加工工艺、智能集成各环节的关键技术，强化工艺基础研究平台建设，关注技术创新和人才培养的多维度结合，以促进激光去除与连接技术从工艺应用开发到装备市场保障的生态链式的协同发展。

关键词：激光加工激光焊接激光切割激光打孔激光打标

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Study on micro-texture and skid resistance of aggregate during polishing

Zhenyu QIAN, Lingjian MENG

《结构与土木工程前沿（英文）》 2017年第11卷第3期页码 346-352 doi: 10.1007/s11709-017-0409-7

摘要： The skid resistance performance of pavement is closely related to the micro-texture of pavement aggregate, while there is very few research on the relationship between micro-texture and the skid resistance. In this paper, the optical microscope is used to acquire the surface morphology of three types of aggregates including basalt, limestone and red sandstone respectively, where a total of 12 indicators are developed based on the surface texture information. The polishing effect on aggregate is simulated by Wehner/Schulze (W/S) device, during the polishing procedure, the skid resistance are measured by British Pendulum Tester (BPT). Based on the results of independent T-test and the polishing resistance analysis, it shows that the surface texture of basalt is significantly different between limestone and red sandstone. Three indicators including the average roughness ( ), the kurtosis of the surface ( ) and the mean summit curvature ( ) are selected to describe the characteristics of aggregate micro-texture based on the correlation analysis. The contribution of micro-texture to the skid resistance can be described with the secondary polynomial regression model by these indicators.

关键词： skid resistance of pavement micro-texture aggregates polishing test

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Temperature field simulation of laser homogenizing equipment

Juanjuan WANG, Yunshan WANG, Fudong ZHU

《机械工程前沿（英文）》 2009年第4卷第1期页码 49-52 doi: 10.1007/s11465-009-0005-1

摘要： The laser homogenizing equipment was devised using the ring scanning principle. Its working principle is explained. A laser scanning ring facula is obtained when the laser beam goes through the equipment’s optical system rotating with high-frequency. The scanning ring facula’s mathematic model is established based on the temperature field’s superposing principle. The ring facula’s light intensity distribution and temperature distribution characteristics are achieved by simulating its temperature field. By studying the effect of parameters on the temperature field, the best parameter can be found. Results show that favorable temperature distribution characteristics can be attained by choosing appropriate parameters, and even the thermal effect can be realized by utilizing the circumference power compensating for the heat exchange lost in the horizontal direction. The uniform hardness layer and better process quality can be attained using the ring facula optimized for metal laser heat treatment.

关键词： laser homogenizing technology laser scanning ring facula temperature field

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我国激光技术与应用2035 发展战略研究

“我国激光技术与应用2035 发展战略研究”项目综合组

《中国工程科学》 2020年第22卷第3期页码 1-6 doi: 10.15302/J-SSCAE-2020.03.001

摘要：

为促进激光技术及应用的发展，中国工程院于2018 年启动了“我国激光技术与应用2035 发展战略研究”重点咨询项目，本文是项目研究综合报告，文章简要分析了激光技术及在科研与产业中的工具性、引领性和颠覆性作用，分析了我国激光技术在前沿激光、制造加工、信息通信、医疗诊治等领域的科研和应用的发展现状，梳理了多个制约加速发展的问题，提出了我国激光技术及应用2035 年发展目标设想：强化顶层统筹谋划，引领我国激光技术与应用产业快速发展；加强基础研究，聚力突破产业化发展中的重大基础问题、共性技术基础和基础材料、器件；设立应用研发专项，打造多个新激光产业链；创新产业协同机制，完善激光产业创新生态；强化激光基础教育，加大对激光及光学学科人才培养力度等政策措施建议。

关键词：激光技术激光制造激光通信激光诊疗

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Processing parameter optimization of fiber laser beam welding using an ensemble of metamodels and MOABC

《机械工程前沿（英文）》 2022年第17卷第4期 doi: 10.1007/s11465-022-0703-5

摘要： In fiber laser beam welding (LBW), the selection of optimal processing parameters is challenging and plays a key role in improving the bead geometry and welding quality. This study proposes a multi-objective optimization framework by combining an ensemble of metamodels (EMs) with the multi-objective artificial bee colony algorithm (MOABC) to identify the optimal welding parameters. An inverse proportional weighting method that considers the leave-one-out prediction error is presented to construct EM, which incorporates the competitive strengths of three metamodels. EM constructs the correlation between processing parameters (laser power, welding speed, and distance defocus) and bead geometries (bead width, depth of penetration, neck width, and neck depth) with average errors of 10.95%, 7.04%, 7.63%, and 8.62%, respectively. On the basis of EM, MOABC is employed to approximate the Pareto front, and verification experiments show that the relative errors are less than 14.67%. Furthermore, the main effect and the interaction effect of processing parameters on bead geometries are studied. Results demonstrate that the proposed EM-MOABC is effective in guiding actual fiber LBW applications.

关键词： laser beam welding parameter optimization metamodel multi-objective

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Development of lunar regolith composite and structure via laser-assisted sintering

《机械工程前沿（英文）》 doi: 10.1007/s11465-021-0662-2

摘要： Aiming at the exploration and resource utilization activities on the Moon, in situ resource utilization and in situ manufacturing are proposed to minimize the dependence on the ground transportation supplies. In this paper, a laser-assisted additive manufacturing process is developed to fabricate lunar regolith composites with PA12/SiO₂ mixing powders. The process parameters and composite material compositions are optimized in an appropriate range through orthogonal experiments to establish the relationship of process–structure–property for lunar regolith composites. The optimal combination of composite material compositions and process parameters are mixing ratio of 50/50 in volume, laser power of 30 W, scanning speed of 3500 mm/s, and scanning hatch space of 0.2 mm. The maximum tensile strength of lunar regolith composites reaches 9.248 MPa, and the maximum depth of surface variation is 120.79 μm, which indicates poor powder fusion and sintering quality. Thereafter, the mechanical properties of laser-sintered lunar regolith composites are implemented to the topology optimization design of complex structures. The effectiveness and the feasibility of this laser-assisted process are potentially developed for future lightweight design and manufacturing of the solar panel installed on the lunar rover.

关键词： in situ manufacturing laser-assisted powder fusion process mechanical properties topological structure design

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激光表面改性技术发展研究

张群莉,王梁,梅雪松,姚建华

《中国工程科学》 2020年第22卷第3期页码 71-77 doi: 10.15302/J-SSCAE-2020.03.010

摘要：

激光表面改性技术利用高能量密度的激光束对零部件局部易损易耗区域进行快速处理，获得材料表面所需性能，进而大幅延长零部件使用寿命，已在航空航天、石油化工、能源、交通、冶金等领域获得应用。本文针对激光冲击强化、激光淬火、激光熔覆3 种典型的激光表面改性技术，梳理了相应技术特点及国内外应用现状，凝练我国相关技术领域面临的差距与问题，总结激光表面改性技术的重点发展方向：专用合金材料制备、多能场激光复合表面改性、面向现场的激光再制造、激光冲击强化控形控性、激光表面改性智能化、激光表面微结构化。从政府引导、国产化创新、产业链完善、质量评价标准体系、人才培养等方面提出发展建议，以期为我国激光表面改性技术发展提供参考借鉴。

关键词：激光表面改性冲击强化淬火熔覆发展趋势

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zone-layered trimming method for ceramic core of aero-engine blade based on an advanced reconfigurable laser

《机械工程前沿（英文）》 2022年第17卷第2期 doi: 10.1007/s11465-022-0675-5

摘要： Ceramic structural parts are one of the most widely utilized structural parts in the industry. However, they usually contain defects following the pressing process, such as burrs. Therefore, additional trimming is usually required, despite the deformation challenges and difficulty in positioning. This paper proposes an ultrafast laser processing system for trimming complex ceramic structural parts. Opto-electromechanical cooperative control software is developed to control the laser processing system. The trimming problem of the ceramic cores used in aero engines is studied. The regional registration method is introduced based on the iterative closest point algorithm to register the path extracted from the computer-aided design model with the deformed ceramic core. A zonal and layering processing method for three-dimensional contours on complex surfaces is proposed to generate the working data of high-speed scanning galvanometer and the computer numerical control machine tool, respectively. The results show that the laser system and the method proposed in this paper are suitable for trimming complex non-datum parts such as ceramic cores. Compared with the results of manual trimming, the method proposed in this paper has higher accuracy, efficiency, and yield. The method mentioned above has been used in practical application with satisfactory results.

关键词： ceramic parts trimming computer-aided laser manufacturing 3D vision reconfigurable laser processing system

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Hybrid forming mechanism of patternless casting and laser cladding

Zhongde SHAN, Fuzhen SUN, Yang LIU

《机械工程前沿（英文）》 2019年第14卷第4期页码 393-401 doi: 10.1007/s11465-019-0550-1

摘要： In accordance with the requirement of manufacturing dies quickly and economically, a hybrid forming method of stamping dies for automobile panels is proposed. The method combines digital patternless casting and high-power laser cladding. An experimental study is conducted on the hybrid forming process and its trial production and application in the manufacturing of stamping dies for typical panels. Results prove that the laser cladding layer exceeds HRC60 (Rockwell hardness) and thus meets the production efficiency requirement of automobile dies. The rate of defects is well controlled. Compared with traditional technology, this technology has remarkable advantages and advancement.

关键词： patternless casting laser cladding hybrid forming rapid tooling