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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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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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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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Tribological mechanism of carbon group nanofluids on grinding interface under minimum quantity lubrication

《机械工程前沿（英文）》 2023年 第18卷 第1期 doi: 10.1007/s11465-022-0733-z

摘要： Carbon group nanofluids can further improve the friction-reducing and anti-wear properties of minimum quantity lubrication (MQL). However, the formation mechanism of lubrication films generated by carbon group nanofluids on MQL grinding interfaces is not fully revealed due to lack of sufficient evidence. Here, molecular dynamic simulations for the abrasive grain/workpiece interface were conducted under nanofluid MQL, MQL, and dry grinding conditions. Three kinds of carbon group nanoparticles, i.e., nanodiamond (ND), carbon nanotube (CNT), and graphene nanosheet (GN), were taken as representative specimens. The [BMIM]BF4 ionic liquid was used as base fluid. The materials used as workpiece and abrasive grain were the single-crystal Ni–Fe–Cr series of Ni-based alloy and single-crystal cubic boron nitride (CBN), respectively. Tangential grinding force was used to evaluate the lubrication performance under the grinding conditions. The abrasive grain/workpiece contact states under the different grinding conditions were compared to reveal the formation mechanism of the lubrication film. Investigations showed the formation of a boundary lubrication film on the abrasive grain/workpiece interface under the MQL condition, with the ionic liquid molecules absorbing in the groove-like fractures on the grain wear’s flat face. The boundary lubrication film underwent a friction-reducing effect by reducing the abrasive grain/workpiece contact area. Under the nanofluid MQL condition, the carbon group nanoparticles further enhanced the tribological performance of the MQL technique that had benefited from their corresponding tribological behaviors on the abrasive grain/workpiece interface. The behaviors involved the rolling effect of ND, the rolling and sliding effects of CNT, and the interlayer shear effect of GN. Compared with the findings under the MQL condition, the tangential grinding forces could be further reduced by 8.5%, 12.0%, and 14.1% under the diamond, CNT, and graphene nanofluid MQL conditions, respectively.

关键词： grinding     minimum quantity lubrication     carbon group nanofluid     tribological mechanism    

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Mechanical behavior and semiempirical force model of aerospace aluminum alloy milling using nano biological

《机械工程前沿（英文）》 2023年 第18卷 第1期 doi: 10.1007/s11465-022-0720-4

摘要： Aerospace aluminum alloy is the most used structural material for rockets, aircraft, spacecraft, and space stations. The deterioration of surface integrity of dry machining and the insufficient heat transfer capacity of minimal quantity lubrication have become the bottleneck of lubrication and heat dissipation of aerospace aluminum alloy. However, the excellent thermal conductivity and tribological properties of nanofluids are expected to fill this gap. The traditional milling force models are mainly based on empirical models and finite element simulations, which are insufficient to guide industrial manufacturing. In this study, the milling force of the integral end milling cutter is deduced by force analysis of the milling cutter element and numerical simulation. The instantaneous milling force model of the integral end milling cutter is established under the condition of dry and nanofluid minimal quantity lubrication (NMQL) based on the dual mechanism of the shear effect on the rake face of the milling cutter and the plow cutting effect on the flank surface. A single factor experiment is designed to introduce NMQL and the milling feed factor into the instantaneous milling force coefficient. The average absolute errors in the prediction of milling forces for the NMQL are 13.3%, 2.3%, and 7.6% in the x-, y-, and z-direction, respectively. Compared with the milling forces obtained by dry milling, those by NMQL decrease by 21.4%, 17.7%, and 18.5% in the x-, y-, and z-direction, respectively.

关键词： milling     force     nanofluid minimum quantity lubrication     aerospace aluminum alloy     nano biological lubricant    

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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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Recent progress in electric-field assisted combustion: a brief review

《能源前沿（英文）》 2022年 第16卷 第6期   页码 883-899 doi: 10.1007/s11708-021-0770-z

摘要： The control of combustion is a hot and classical topic. Among the combustion technologies, electric-field assisted combustion is an advanced techno-logy that enjoys major advantages such as fast response and low power consumption compared with thermal power. However, its fundamental principle and impacts on the flames are complicated due to the coupling between physics, chemistry, and electromagnetics. In the last two decades, tremendous efforts have been made to understand electric-field assisted combustion. New observations have been reported based on different combustion systems and improved diagnostics. The main impacts, including flame stabilization, emission reduction, and flame propagation, have been revealed by both simulative and experimental studies. These findings significantly facilitate the application of electric-field assisted combustion. This brief review is intended to provide a comprehensive overview of the recent progress of this combustion technology and further point out research opportunities worth investigation.

关键词： electric field     combustion     flame stabilization     emission reduction     flame propagation    

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A review of cryogenic power generation cycles with liquefied natural gas cold energy utilization

Feier XUE,Yu CHEN,Yonglin JU

《能源前沿（英文）》 2016年 第10卷 第3期   页码 363-374 doi: 10.1007/s11708-016-0397-7

摘要： Liquefied natural gas (LNG), an increasingly widely applied clean fuel, releases a large number of cold energy in its regasification process. In the present paper, the existing power generation cycles utilizing LNG cold energy are introduced and summarized. The direction of cycle improvement can be divided into the key factors affecting basic power generation cycles and the structural enhancement of cycles utilizing LNG cold energy. The former includes the effects of LNG-side parameters, working fluids, and inlet and outlet thermodynamic parameters of equipment, while the latter is based on Rankine cycle, Brayton cycle, Kalina cycle and their compound cycles. In the present paper, the diversities of cryogenic power generation cycles utilizing LNG cold energy are discussed and analyzed. It is pointed out that further researches should focus on the selection and component matching of organic mixed working fluids and the combination of process simulation and experimental investigation, etc.

关键词： liquefied natural gas (LNG) cold energy     power generation cycle     Rankine cycle     compound cycle    

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Initial impacts of rain gardens’ application on water quality and quantity in combined sewer: field-scale

Isam Alyaseri, Jianpeng Zhou, Susan M. Morgan, Andrew Bartlett

《环境科学与工程前沿（英文）》 2017年 第11卷 第4期 doi: 10.1007/s11783-017-0988-5

摘要： Green infrastructures such as rain gardens can benefit onsite reduction of stormwater runoff, leading to reduced combined sewer overflows. A pilot project was conducted to evaluate the impact of rain gardens on the water quality and volume reduction of storm runoff from urban streets in a combined sewer area. The study took place in a six-block area on South Grand Boulevard in St. Louis, Missouri. The impact was assessed through a comparison between the pre-construction (2011/2012) and the post-construction (2014) phases. Shortly after the rain gardens were installed, the levels of total suspended solids, chloride, total nitrogen, total phosphorous, zinc, and copper increased. The level of mercury was lower than the detection level in both phases. was the only parameter that showed statistically significant decrease following the installation of rain gardens. The likely reason for initial increase in monitored water quality parameters is that the post-construction sampling began after the rain gardens were constructed but before planting, resulted from soil erosion and wash-out from the mulch. However, the levels of most of water quality parameters decreased in the following time period during the post-construction phase. The study found 76% volume reduction of stormwater runoff following the installation of rain gardens at one of studied sites. Statistical analysis is essential on collected data because of the encountered high variability of measured flows resulted from low flow conditions in studied sewers.

关键词： Rain gardens     Bioretention     Combined sewer     Stormwater quality and quantity    

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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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Study on the microwave-assisted extraction of polyphenols from tea

Liyun WANG, Peiyong QIN, Yan HU,

《化学科学与工程前沿（英文）》 2010年 第4卷 第3期   页码 307-313 doi: 10.1007/s11705-009-0282-6

摘要： This study demonstrated a promising method for quickly extracting tea polyphenol (TP) by microwave-assisted extraction (MAE) technology. Some influential parameters, including MAE temperature, microwave power, concentration of extraction solvent, MAE time and the solid/liquid ratio, were investigated. The optimum condition of MAE was obtained by dual extraction with 60% ethanol (v/v) and the solid/liquid ratio 1:12 g/mL at 80°C for 10 minutes under the microwave power 600 W. The yield of TP was 96.5% under the described condition. Compared with traditional methods, including hot reflux extraction (HRE), ultrasound-assisted extraction (UAE) and supercritical fluid extraction (SFE), the extraction time was saved 8 times than that of HRE, and the yield was increased by 17.5%. The extraction time at comparable levels of production was saved 2 times, and the energy consumption was one fourth that of UAE. The extraction time was saved 5 times than that of SFE, and the yield of TP was increased by 40%. Moreover, compared with MAE of TP studied by others, it decreased the solid/liquid ratio from 1 ∶ 20 to 1 ∶ 12 g/mL without 90-min pre-leaching time, and the yield of TP was increased by 6%–40%.

关键词： energy consumption     microwave-assisted extraction     optimum condition     pre-leaching     concentration    

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Near-field radiative thermoelectric energy converters: a review

Eric TERVO, Elham BAGHERISERESHKI, Zhuomin ZHANG

《能源前沿（英文）》 2018年 第12卷 第1期   页码 5-21 doi: 10.1007/s11708-017-0517-z

摘要： Radiative thermoelectric energy converters, which include thermophotovoltaic cells, thermoradiative cells, electroluminescent refrigerators, and negative electroluminescent refrigerators, are semiconductor p-n devices that either generate electricity or extract heat from a cold body while exchanging thermal radiation with their surroundings. If this exchange occurs at micro or nanoscale distances, power densities can be greatly enhanced and near-field radiation effects may improve performance. This review covers the fundamentals of near-field thermal radiation, photon entropy, and nonequilibrium effects in semiconductor diodes that underpin device operation. The development and state of the art of these near-field converters are discussed in detail, and remaining challenges and opportunities for progress are identified.

关键词： energy conversion systems     luminescent refrigeration     near-field radiation     thermophotovoltaic     thermoradiative cell    

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Effect of Fe loading quantity on reduction reactivity of nano zero-valent iron supported on chelating

Jialu SHI,Shengnan YI,Chao LONG,Aimin LI

《环境科学与工程前沿（英文）》 2015年 第9卷 第5期   页码 840-849 doi: 10.1007/s11783-015-0781-2

摘要： In this study, nanoscale zero-valent iron (NZVI) were immobilized within a chelating resin (DOW 3N). To investigate the effect of Fe loading on NZVI reactivity, three NZVI-resin composites with different Fe loading were obtained by preparing Fe(III) solution in 0, 30 and 70% (v/v) ethanol aqueous, respectively; the bromate was used as a model contaminant. TEM reveals that increasing the Fe loading resulted in much larger size and poor dispersion of nanoscale iron particles. The results indicated that the removal efficiency of bromate and the rate constant ( ) were decreased with increasing the Fe loading. For the NZVI-resin composite with lower Fe loading, the removal efficiency of bromate declined more significantly with the increase of DO concentrations. Under acidic conditions, decreasing the pH value had the most significant influence on NZVI-R3 with highest Fe loading for bromate removal; however, under alkaline conditions, the most significant influence of pH was on NZVI-R1 with lowest Fe loading. The effects of co-existing anions , and were also investigated. All of the co-existing anions showed the inhibition to bromate reduction.

关键词： nanoscale zero valent iron     loading quantity     reduction     chelating resin     bromated    

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消费领域用能特征探究

江亿,朱安东,郭偲悦

《中国工程科学》 2015年 第17卷 第8期   页码 122-131

摘要：

根据使用过程特征，可以将用能行为分成生产领域用能与消费领域用能。前者提供产品，后者提供服务。消费领域与生产领域用能存在不同特征，其评价方法、节能途径、战略政策等也存在差别。考虑到这一领域能耗可能是我国下一阶段能耗增长点，在节能领域需要对其给予足够的重视。本文在分析消费领域用能特征的基础上，提出对其的衡量方式和节能途径，并针对我国目前消费领域用能的现状给出建议。

关键词： 消费领域；生产领域；能耗；特征    

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Review on cryogenic technologies for CO removal from natural gas

Yujing BI, Yonglin JU

《能源前沿（英文）》 2022年 第16卷 第5期   页码 793-811 doi: 10.1007/s11708-022-0821-0

摘要： CO2 in natural gas (NG) is prone to condense directly from gas to solid or solidify from liquid to solid at low temperatures due to its high triple point and boiling temperature, which can cause a block of equipment. Meanwhile, CO2 will also affect the calorific value of NG. Based on the above reasons, CO2 must be removed during the NG liquefaction process. Compared with conventional methods, cryogenic technologies for CO2 removal from NG have attracted wide attention due to their non-polluting and low-cost advantages. Its integration with NG liquefaction can make rational use of the cold energy and realize the purification of NG and the production of by-product liquid CO2. In this paper, the phase behavior of the CH4-CO2 binary mixture is summarized, which provides a basis for the process design of cryogenic CO2 removal from NG. Then, the detailed techniques of design and optimization for cryogenic CO2 removal in recent years are summarized, including the gas-liquid phase change technique and the gas-solid phase change technique. Finally, several improvements for further development of the cryogenic CO2 removal process are proposed. The removal process in combination with the phase change and the traditional techniques with renewable energy will be the broad prospect for future development.

关键词： cryogenic CO2 removal     purification of natural gas (NG)     biogas upgrading     CH4-CO2 binary system    

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标题 作者 时间 类型 操作

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

期刊论文

Cryogenic minimum quantity lubrication machining: from mechanism to application

期刊论文

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

期刊论文

Tribological mechanism of carbon group nanofluids on grinding interface under minimum quantity lubrication

期刊论文

Mechanical behavior and semiempirical force model of aerospace aluminum alloy milling using nano biological

期刊论文

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

期刊论文

Recent progress in electric-field assisted combustion: a brief review

期刊论文

A review of cryogenic power generation cycles with liquefied natural gas cold energy utilization

Feier XUE,Yu CHEN,Yonglin JU

期刊论文

Initial impacts of rain gardens’ application on water quality and quantity in combined sewer: field-scale

Isam Alyaseri, Jianpeng Zhou, Susan M. Morgan, Andrew Bartlett

期刊论文

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

期刊论文

Study on the microwave-assisted extraction of polyphenols from tea

Liyun WANG, Peiyong QIN, Yan HU,

期刊论文

Near-field radiative thermoelectric energy converters: a review

Eric TERVO, Elham BAGHERISERESHKI, Zhuomin ZHANG

期刊论文

Effect of Fe loading quantity on reduction reactivity of nano zero-valent iron supported on chelating

Jialu SHI,Shengnan YI,Chao LONG,Aimin LI

期刊论文

消费领域用能特征探究

江亿,朱安东,郭偲悦

期刊论文

Review on cryogenic technologies for CO removal from natural gas

Yujing BI, Yonglin JU

期刊论文