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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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Assessing the effects of different dielectrics on environmentally conscious powder-mixed EDM of difficult-to-machinematerial (WC-Co)

Jagdeep SINGH,Rajiv Kumar SHARMA

《机械工程前沿（英文）》 2016年第11卷第4期页码 374-387 doi: 10.1007/s11465-016-0388-8

摘要：

Electrical discharge machining (EDM) is a well-known nontraditional manufacturing process to machine the difficult-to-machine (DTM) materials which have unique hardness properties. Researchers have successfully performed hybridization to improve this process by incorporating powders into the EDM process known as powder-mixed EDM process. This process drastically improves process efficiency by increasing material removal rate, micro-hardness, as well as reducing the tool wear rate and surface roughness. EDM also has some input parameters, including pulse-on time, dielectric levels and its type, current setting, flushing pressure, and so on, which have a significant effect on EDM performance. However, despite their positive influence, investigating the effects of these parameters on environmental conditions is necessary. Most studies demonstrate the use of kerosene oil as dielectric fluid. Nevertheless, in this work, the authors highlight the findings with respect to three different dielectric fluids, including kerosene oil, EDM oil, and distilled water using one-variable-at-a-time approach for machining as well as environmental aspects. The hazard and operability analysis is employed to identify the inherent safety factors associated with powder-mixed EDM of WC-Co.

关键词： WC hazard and operability analysis (HAZOP) discharging aerosol concentration dielectrics powders

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Comparative assessment of force, temperature, and wheel wear in sustainable grinding aerospace alloy using biolubricant

《机械工程前沿（英文）》 2023年第18卷第1期 doi: 10.1007/s11465-022-0719-x

摘要： The substitution of biolubricant for mineral cutting fluids in aerospace material grinding is an inevitable development direction, under the requirements of the worldwide carbon emission strategy. However, serious tool wear and workpiece damage in difficult-to-machine material grinding challenges the availability of using biolubricants via minimum quantity lubrication. The primary cause for this condition is the unknown and complex influencing mechanisms of the biolubricant physicochemical properties on grindability. In this review, a comparative assessment of grindability is performed using titanium alloy, nickel-based alloy, and high-strength steel. Firstly, this work considers the physicochemical properties as the main factors, and the antifriction and heat dissipation behaviours of biolubricant in a high temperature and pressure interface are comprehensively analysed. Secondly, the comparative assessment of force, temperature, wheel wear and workpiece surface for titanium alloy, nickel-based alloy, and high-strength steel confirms that biolubricant is a potential replacement of traditional cutting fluids because of its improved lubrication and cooling performance. High-viscosity biolubricant and nano-enhancers with high thermal conductivity are recommended for titanium alloy to solve the burn puzzle of the workpiece. Biolubricant with high viscosity and high fatty acid saturation characteristics should be used to overcome the bottleneck of wheel wear and nickel-based alloy surface burn. The nano-enhancers with high hardness and spherical characteristics are better choices. Furthermore, a different option is available for high-strength steel grinding, which needs low-viscosity biolubricant to address the debris breaking difficulty and wheel clogging. Finally, the current challenges and potential methods are proposed to promote the application of biolubricant.

关键词： grinding aerospace difficult-to-machine material biolubricant physicochemical property grindability

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Liquid metal material genome: Initiation of a new research track towards discovery of advanced energy

Lei WANG, Jing LIU

《能源前沿（英文）》 2013年第7卷第3期页码 317-332 doi: 10.1007/s11708-013-0271-9

摘要： As the basis of modern industry, the roles materials play are becoming increasingly vital in this day and age. With many superior physical properties over conventional fluids, the low melting point liquid metal material, especially room-temperature liquid metal, is recently found to be uniquely useful in a wide variety of emerging areas from energy, electronics to medical sciences. However, with the coming enormous utilization of such materials, serious issues also arise which urgently need to be addressed. A biggest concern to impede the large scale application of room-temperature liquid metal technologies is that there is currently a strong shortage of the materials and species available to meet the tough requirements such as cost, melting point, electrical and thermal conductivity, etc. Inspired by the Material Genome Initiative as issued in 2011 by the United States of America, a more specific and focused project initiative was proposed in this paper—the liquid metal material genome aimed to discover advanced new functional alloys with low melting point so as to fulfill various increasing needs. The basic schemes and road map for this new research program, which is expected to have a worldwide significance, were outlined. The theoretical strategies and experimental methods in the research and development of liquid metal material genome were introduced. Particularly, the calculation of phase diagram (CALPHAD) approach as a highly effective way for material design was discussed. Further, the first-principles (FP) calculation was suggested to combine with the statistical thermodynamics to calculate the thermodynamic functions so as to enrich the CALPHAD database of liquid metals. When the experimental data are too scarce to perform a regular treatment, the combination of FP calculation, cluster variation method (CVM) or molecular dynamics (MD), and CALPHAD, referred to as the mixed FP-CVM-CALPHAD method can be a promising way to solve the problem. Except for the theoretical strategies, several parallel processing experimental methods were also analyzed, which can help improve the efficiency of finding new liquid metal materials and reducing the cost. The liquid metal material genome proposal as initiated in this paper will accelerate the process of finding and utilization of new functional materials.

关键词： liquid metal material genome energy material material discovery advanced material room-temperature liquid alloy thermodynamics phase diagram

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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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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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Experimental research on ductile fracture criterion in metal forming

Song YU, Weiming FENG

《机械工程前沿（英文）》 2011年第6卷第3期页码 308-311 doi: 10.1007/s11465-011-0233-z

摘要：

Ductile fracture criterion is key limitation parameter in material forming. Accuracy predicting surface and internal failure in plastic deformation process affects on the technology design of workpiece and die greatly. Tension, compression, torsion and shearing test on 45# steel are utilized for providing the experimental values of the critical values at fracture, and 11 widely used ductile fracture criterion are selected to simulate the physical experiments and their relative accuracy for predicting and quantifying fracture initiation sites are investigated. The comparing results show that metal forming process under high triaxiality can be estimated successively using both Normalized Cockcroft-latham and the Brozzo ductile fracture criteria, but the Ayada and general Rice-Tracey model work very well for the low triaxiality cases.

关键词： ductile fracture criteria metal forming process material experiment stress triaxiality

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Win-Win: Anthropogenic circularity for metal criticality and carbon neutrality

《环境科学与工程前沿（英文）》 2023年第17卷第2期 doi: 10.1007/s11783-023-1623-2

摘要：

● Anthropogenic circularity science is an emerging interdisciplinary field.

关键词： Anthropogenic circularity Material flow analysis Criticality Carbon neutrality Solid waste Circular economy

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Surface tension of liquid metal: role, mechanism and application

Xi ZHAO, Shuo XU, Jing LIU

《能源前沿（英文）》 2017年第11卷第4期页码 535-567 doi: 10.1007/s11708-017-0463-9

摘要： Surface tension plays a core role in dominating various surface and interface phenomena. For liquid metals with high melting temperature, a profound understanding of the behaviors of surface tension is crucial in industrial processes such as casting, welding, and solidification, etc. Recently, the room temperature liquid metal (RTLM) mainly composed of gallium-based alloys has caused widespread concerns due to its increasingly realized unique virtues. The surface properties of such materials are rather vital in nearly all applications involved from chip cooling, thermal energy harvesting, hydrogen generation, shape changeable soft machines, printed electronics to 3D fabrication, etc. owing to its pretty large surface tension of approximately 700 mN/m. In order to promote the research of surface tension of RTLM, this paper is dedicated to present an overview on the roles and mechanisms of surface tension of liquid metal and summarize the latest progresses on the understanding of the basic knowledge, theories, influencing factors and experimental measurement methods clarified so far. As a practical technique to regulate the surface tension of RTLM, the fundamental principles and applications of electrowetting are also interpreted. Moreover, the unique phenomena of RTLM surface tension issues such as surface tension driven self-actuation, modified wettability on various substrates and the functions of oxides are discussed to give an insight into the acting mechanism of surface tension. Furthermore, future directions worthy of pursuing are pointed out.

关键词： surface tension liquid metal soft machine printed electronics electrowetting self-actuation

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High heat flux thermal management through liquid metal driven with electromagnetic induction pump

《能源前沿（英文）》 2022年第16卷第3期页码 460-470 doi: 10.1007/s11708-022-0825-9

摘要： In this paper, a novel liquid metal-based minichannel heat dissipation method was developed for cooling electric devices with high heat flux. A high-performance electromagnetic induction pump driven by rotating permanent magnets is designed to achieve a pressure head of 160 kPa and a flow rate of 3.24 L/min, which could enable the liquid metal to remove the waste heat quickly. The liquid metal-based minichannel thermal management system was established and tested experimentally to investigate the pumping capacity and cooling performance. The results show that the liquid metal cooling system can dissipate heat flux up to 242 W/cm² with keeping the temperature rise of the heat source below 50°C. It could remarkably enhance the cooling performance by increasing the rotating speed of permanent magnets. Moreover, thermal contact resistance has a critical importance for the heat dissipation capacity. The liquid metal thermal grease is introduced to efficiently reduce the thermal contact resistance (a decrease of about 7.77 × 10⁻³ °C/W). This paper provides a powerful cooling strategy for thermal management of electric devices with large heat power and high heat flux.

关键词： high heat flux liquid metal electromagnetic pump minichannel heat sink thermal interface material

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高性能零件的性能与几何参数一体化精密加工方法与技术

郭东明

《中国工程科学》 2011年第13卷第10期页码 47-57

摘要：

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

关键词：高性能性能与几何参数一体化精密加工难加工材料复杂曲面

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Smart systems engineering contributing to an intelligent carbon-neutral future: opportunities, challenges, and prospects

《化学科学与工程前沿（英文）》 2022年第16卷第6期页码 1023-1029 doi: 10.1007/s11705-022-2142-6

摘要： This communication paper provides an overview of multi-scale smart systems engineering (SSE) approaches and their applications in crucial domains including materials discovery, intelligent manufacturing, and environmental management. A major focus of this interdisciplinary field is on the design, operation and management of multi-scale systems with enhanced economic and environmental performance. The emergence of big data analytics, internet of things, machine learning, and general artificial intelligence could revolutionize next-generation research, industry and society. A detailed discussion is provided herein on opportunities, challenges, and future directions of SSE in response to the pressing carbon-neutrality targets.

关键词： machine learning modeling material industrial applications environment

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三峡工程建设的主要科技难题

王家柱

《中国工程科学》 2003年第5卷第8期页码 16-22

摘要：

三峡工程是世界最大的多目标开发的综合利用工程。工程规模巨大，技术复杂，具有防洪、发电、航运等巨大的综合效益。文章论述了工程建设过程中已经和将要解决的一大批重大科学技术难题，并指出其将对水利水电科学技术的发展起到重要的促进作用。

关键词：三峡工程科技难题

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多尺度材料与过程设计的数据驱动和机理混合建模方法 Perspective

周腾, Rafiqul Gani, Kai Sundmacher

《工程（英文）》 2021年第7卷第9期页码 1231-1238 doi: 10.1016/j.eng.2020.12.022

摘要：

世界人口的不断增长要求加工业以更高效和更可持续的方式生产食品、燃料、化学品和消费品。功能性过程材料是这一挑战的核心。传统上，人们根据经验或者通过反复试验的方法来发现新型先进材料。随着理论方法和相关工具的不断改进和计算机能力的提高，现在流行使用计算方法来指导材料选择和设计，这种方法也非常有效。由于材料选择与材料使用的过程操作之间存在很强的相互作用，必须同时进行材料设计和过程设计。尽管有这种重要联系，但由于通常需要使用不同规模的多个模型，材料和过程的集成设计并不容易。混合建模为解决此类复杂的设计问题提供了一个有前景的选择。在混合建模中，用数据驱动模型描述原本计算成本高昂的材料特性，而用机理模型表示众所周知的过程相关原理。本文重点介绍了混合建模在多尺度材料和过程设计中的重要性。首先介绍通用设计方法，然后选择了六个重要的应用领域：四个来自化学工程领域，两个来自能源系统工程领域。对于选定的每个领域，讨论了使用混合建模进行多尺度材料和过程设计的最新研究。最后，本文给出了结论，指出当前研究的局限性和未来的发展空间。

关键词：数据驱动代理模型机器学习混合建模材料设计过程优化

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汽车板精益成形技术

林忠钦,李淑慧,王武荣,来新民

《中国工程科学》 2009年第11卷第11期页码 22-29

摘要：

建立了面向零件成形特征的合理选材方法，发明了高效的拉延筋阻力混合优化设计方法，构建了变压边力控制实验平台。从降低成形质量对材料和工艺过程波动敏感性的角度出发，研究面向材料和工艺参数随机波动的成形质量的稳健控制。形成了基于“合理选材、工艺优化、稳健设计”思想的汽车板精益成形技术体系。通过在宝钢股份和多家汽车厂10多年的成功应用，支持宝钢汽车板的市场占有率稳步达到50 %，有效地推动了国产汽车板使用技术的发展。

关键词：汽车板精益成形合理选材工艺优化稳健设计