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Ion beam figuring of continuous phase plates based on the frequency filtering process

Mingjin XU,Yifan DAI,Xuhui XIE,Lin ZHOU,Shengyi LI,Wenqiang PENG

《机械工程前沿（英文）》 2017年 第12卷 第1期   页码 110-115 doi: 10.1007/s11465-017-0430-5

摘要：

Ion beam figuring (IBF) technology is an effective technique for fabricating continuous phase plates (CPPs) with small feature structures. This study proposes a multi-pass IBF approach with different beam diameters based on the frequency filtering method to improve the machining accuracy and efficiency of CPPs during IBF. We present the selection principle of the frequency filtering method, which incorporates different removal functions that maximize material removal over the topographical frequencies being imprinted. Large removal functions are used early in the fabrication to figure the surface profile with low frequency. Small removal functions are used to perform final topographical correction with higher frequency and larger surface gradient. A high-precision surface can be obtained as long as the filtering frequency is suitably selected. This method maximizes the high removal efficiency of the large removal function and the high corrective capability of the small removal function. Consequently, the fast convergence of the machining accuracy and efficiency can be achieved.

关键词： ion beam figuring (IBF)     continuous phase plates (CPPs)     machining accuracy     machining efficiency     frequency filtering process    

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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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Reliability analysis of kinematic accuracy for the elastic slider-crank mechanism

TUO Yaofei, CHEN Jianjun, ZHANG Chijiang, CHEN Yongqin

《机械工程前沿（英文）》 2007年 第2卷 第2期   页码 214-217 doi: 10.1007/s11465-007-0037-3

摘要： This paper deals with the static and dynamic output kinematic accuracy of a group of elastic slider-crank mechanisms with the same design parameters by taking the bar length, the joint-gaps, the mass density, and the sectional and the physical parameters as random variables. According to the principle of linear pile-up of small displacement, the static and dynamic output kinematic errors are synthesized, and the reliability model of the kinematic accuracy of the mechanism is built. Through an example, a study of the influencing factors on the reliability of the output kinematic accuracy of the mechanism is made. The results obtained reveal the following facts: with the increase of the crank s rotating speed, the dynamic elastic deformation of the mechanism becomes the principal factor that greatly affects the reliability of the output kinematic accuracy of the mechanism.

关键词： output kinematic     group     slider-crank     kinematic accuracy     displacement    

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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    

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Simulation of abrasive flow machining process for 2D and 3D mixture models

Rupalika DASH,Kalipada MAITY

《机械工程前沿（英文）》 2015年 第10卷 第4期   页码 424-432 doi: 10.1007/s11465-015-0366-6

摘要：

Improvement of surface finish and material removal has been quite a challenge in a finishing operation such as abrasive flow machining (AFM). Factors that affect the surface finish and material removal are media viscosity, extrusion pressure, piston velocity, and particle size in abrasive flow machining process. Performing experiments for all the parameters and accurately obtaining an optimized parameter in a short time are difficult to accomplish because the operation requires a precise finish. Computational fluid dynamics (CFD) simulation was employed to accurately determine optimum parameters. In the current work, a 2D model was designed, and the flow analysis, force calculation, and material removal prediction were performed and compared with the available experimental data. Another 3D model for a swaging die finishing using AFM was simulated at different viscosities of the media to study the effects on the controlling parameters. A CFD simulation was performed by using commercially available ANSYS FLUENT. Two phases were considered for the flow analysis, and multiphase mixture model was taken into account. The fluid was considered to be a Newtonian fluid and the flow laminar with no wall slip.

关键词： abrasive flow machining (AFM)     computational fluid dynamics (CFD) modeling     mixture model    

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A review of low-temperature plasma-assisted machining: from mechanism to application

《机械工程前沿（英文）》 2023年 第18卷 第1期 doi: 10.1007/s11465-022-0734-y

摘要： Materials with high hardness, strength or plasticity have been widely used in the fields of aviation, aerospace, and military, among others. However, the poor machinability of these materials leads to large cutting forces, high cutting temperatures, serious tool wear, and chip adhesion, which affect machining quality. Low-temperature plasma contains a variety of active particles and can effectively adjust material properties, including hardness, strength, ductility, and wettability, significantly improving material machinability. In this paper, we first discuss the mechanisms and applications of low-temperature plasma-assisted machining. After introducing the characteristics, classifications, and action mechanisms of the low-temperature plasma, we describe the effects of the low-temperature plasma on different machining processes of various difficult-to-cut materials. The low-temperature plasma can be classified as hot plasma and cold plasma according to the different equilibrium states. Hot plasma improves material machinability via the thermal softening effect induced by the high temperature, whereas the main mechanisms of the cold plasma can be summarized as chemical reactions to reduce material hardness, the hydrophilization effect to improve surface wettability, and the Rehbinder effect to promote fracture. In addition, hybrid machining methods combining the merits of the low-temperature plasma and other energy fields like ultrasonic vibration, liquid nitrogen, and minimum quantity lubrication are also described and analyzed. Finally, the promising development trends of low-temperature plasma-assisted machining are presented, which include more precise control of the heat-affected zone in hot plasma-assisted machining, cold plasma-assisted polishing of metal materials, and further investigations on the reaction mechanisms between the cold plasma and other materials.

关键词： low-temperature plasma     difficult-to-cut material     machinability     hydrophilization effect     Rehbinder effect    

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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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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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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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Effects of inclination angles of disc cutter on machining quality of Nomex honeycomb core in ultrasonic

Yidan WANG, Renke KANG, Yan QIN, Qian MENG, Zhigang DONG

《机械工程前沿（英文）》 2021年 第16卷 第2期   页码 285-297 doi: 10.1007/s11465-021-0631-9

摘要： Ultrasonic cutting with a disc cutter is an advanced machining method for the high-quality processing of Nomex honeycomb core. The machining quality is influenced by ultrasonic cutting parameters, as well as tool orientations, which are determined by the multi-axis machining requirements and the angle control of the cutting system. However, in existing research, the effect of the disc cutter orientation on the machining quality has not been studied in depth, and practical guidance for the use of disc cutters is lacking. In this work, the inclined ultrasonic cutting process with a disc cutter was analyzed, and cutting experiments with different inclination angles were conducted. The theoretical residual height models of the honeycomb core, as a result of the lead and tilt angles, were established and verified with the results obtained by a linear laser displacement sensor. Research shows that the residual height of the honeycomb core, as a result of the tilt angle, is much larger than that as a result of the lead angle. Furthermore, the tearing of the cell wall on the machined surface was observed, and the effects of the ultrasonic vibration, lead angle, and tilt angle on the tear rate and tear length of the cell wall were studied. Experimental results revealed that ultrasonic vibration can effectively decrease the tearing of the cell wall and improve the machining quality. Changes in the tilt angle have less effect than changes in the lead angle on the tearing of the cell wall. The determination of inclination angles should consider the actual processing requirements for the residual height and the machining quality of the cell wall. This study investigates the influence of the inclination angles of a disc cutter on the machining quality of Nomex honeycomb core in ultrasonic cutting and provides guidelines for machining.

关键词： Nomex honeycomb core     disc cutter     inclined ultrasonic cutting     machining quality    

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Prediction of cutting forces in machining of unidirectional glass fiber reinforced plastics composite

Surinder Kumar GILL, Meenu GUPTA, P. S. SATSANGI

《机械工程前沿（英文）》 2013年 第8卷 第2期   页码 187-200 doi: 10.1007/s11465-013-0262-x

摘要：

Machining of plastic materials has become increasingly important in any engineering industry subsequently the prediction of cutting forces. Forces quality has greater influence on components, which are coming in contact with each other. So it becomes necessary to measure and study machined forces and its behavior. In this research work, experimental investigations are conducted to determine the effects of cutting conditions and tool geometry on the cutting forces in the turning of the unidirectional glass fiber reinforced plastics (UD-GFRP) composites. In this experimental study, carbide tool (K10) having different tool nose radius and tool rake angle is used. Experiments are conducted based on the established Taguchi’s technique L18 orthogonal array on a lathe machine. It is found that the depth of cut is the cutting parameter, which has greater influence on cutting forces. The effect of the tool nose radius and tool rake angles on the cutting forces are also considerably significant. Based on statistical analysis, multiple regression model for cutting forces is derived with satisfactory coefficient (R2). This model proved to be highly preferment for predicting cutting forces.

关键词： unidirectional glass fiber reinforced plastics (UD-GFRP) composites     machining     cutting forces (tangential     feed and radial force)     ANOVA     regression modeling     carbide tool (K10)    

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标题 作者 时间 类型 操作

Ion beam figuring of continuous phase plates based on the frequency filtering process

Mingjin XU,Yifan DAI,Xuhui XIE,Lin ZHOU,Shengyi LI,Wenqiang PENG

期刊论文

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

期刊论文

Reliability analysis of kinematic accuracy for the elastic slider-crank mechanism

TUO Yaofei, CHEN Jianjun, ZHANG Chijiang, CHEN Yongqin

期刊论文

Equipment–process–strategy integration for sustainable machining: a review

期刊论文

Energy saving design of the machining unit of hobbing machine tool with integrated optimization

期刊论文

Fixturing technology and system for thin-walled parts machining: a review

期刊论文

Recent advances in micro- and nano-machining technologies

Shang GAO, Han HUANG

期刊论文

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

期刊论文

Simulation of abrasive flow machining process for 2D and 3D mixture models

Rupalika DASH,Kalipada MAITY

期刊论文

A review of low-temperature plasma-assisted machining: from mechanism to application

期刊论文

Cryogenic minimum quantity lubrication machining: from mechanism to application

期刊论文

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

期刊论文

Research progress on ultra-precision machining technologies for soft-brittle crystal materials

Hang GAO,Xu WANG,Dongming GUO,Yuchuan CHEN

期刊论文

Effects of inclination angles of disc cutter on machining quality of Nomex honeycomb core in ultrasonic

Yidan WANG, Renke KANG, Yan QIN, Qian MENG, Zhigang DONG

期刊论文

Prediction of cutting forces in machining of unidirectional glass fiber reinforced plastics composite

Surinder Kumar GILL, Meenu GUPTA, P. S. SATSANGI

期刊论文