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Investigation on drilling-grinding of CFRP

Yanming QUAN, Wenwang ZHONG

《机械工程前沿（英文）》 2009年第4卷第1期页码 60-63 doi: 10.1007/s11465-009-0008-y

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

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

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

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

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

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

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Simulation and analysis of grinding wheel based on Gaussian mixture model

Yulun CHI, Haolin LI

《机械工程前沿（英文）》 2012年第7卷第4期页码 427-432 doi: 10.1007/s11465-012-0350-3

摘要：

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

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

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

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

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

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

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characteristics and machining performance of a novel perforated ultrasonic vibration platform in the grinding

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

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

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

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Modelling of dynamic contact length in rail grinding process

null

《机械工程前沿（英文）》 2014年第9卷第3期页码 242-248 doi: 10.1007/s11465-014-0305-y

摘要：

Rails endure frequent dynamic loads from the passing trains for supporting trains and guiding wheels. The accumulated stress concentrations will cause the plastic deformation of rail towards generating corrugations, contact fatigue cracks and also other defects, resulting in more dangerous status even the derailment risks. So the rail grinding technology has been invented with rotating grinding stones pressed on the rail with defects removal. Such rail grinding works are directed by experiences rather than scientifically guidance, lacking of flexible and scientific operating methods. With grinding control unit holding the grinding stones, the rail grinding process has the characteristics not only the surface grinding but also the running railway vehicles. First of all, it’s important to analyze the contact length between the grinding stone and the rail, because the contact length is a critical parameter to measure the grinding capabilities of stones. Moreover, it’s needed to build up models of railway vehicle unit bonded with the grinding stone to represent the rail grinding car. Therefore the theoretical model for contact length is developed based on the geometrical analysis. And the calculating models are improved considering the grinding car’s dynamic behaviors during the grinding process. Eventually, results are obtained based on the models by taking both the operation parameters and the structure parameters into the calculation, which are suitable for revealing the process of rail grinding by combining the grinding mechanism and the railway vehicle systems.

关键词： rail grinding contact length dynamic model Hamiltonian system grinding stone rail grinding car

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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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深水钻井隔水导管挠曲方程和固有频率的计算及其研究

姜伟

《中国工程科学》 2011年第13卷第5期页码 66-73

摘要：

从深水钻井应用的隔水导管的使用实际情况出发，应用弹塑性力学中的位移复分原理的Ritz法，考虑了隔水导管所受到的轴向张力T和隔水导管受力产生的倾角α以及由于自重q所产生的自重横向分力qsin α和轴向分力qcos α，建立了较为合理的挠曲方程，并且由此得到隔水导管的固有振动频率的简易计算求解方法。由于该挠曲方程结合了钻具的实际情况，其挠曲方程的约束条件采用的是一端铰支、一端自由的形式，因此其研究更接近实际情况，研究旨在为深水钻井隔水导管的合理使用设计和选择，提供一种更快捷实用的方法，对深水钻井作业有一定的指导意义。

关键词：深水钻井隔水导管挠曲方程固有频率形状函数

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川东北优快钻井技术

韩来聚,马广军,赵金海

《中国工程科学》 2010年第12卷第10期页码 44-49

摘要：

川东北地区存在陆相地层可钻性差、高陡构造井斜严重，地层岩性变化大、压力系统复杂、易塌、易漏，“高压、高产、高含硫”勘探风险大等世界级钻井技术难题，造成的钻井复杂情况多、机械钻速慢、钻井周期长。围绕“钻井提速”这一主线，以开发与应用新工艺、新工具提高南方复杂深井钻井速度为目的，从气体钻井和垂直钻井设备引进配套和研发入手，结合已有的欠平衡钻井技术、控压降密度钻井与复合钻井技术，综合应用多种钻井技术全面提高川东北复杂深井钻井速度及井身质量，通过室内实验研究、单项技术试验和综合技术集成，形成了适应川东北地区地层特

关键词：川东北优快钻井气体钻井垂直钻井控压降密度钻井钻头优选复合钻井

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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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Effects of taping on grinding quality of silicon wafers in backgrinding

Zhigang DONG, Qian ZHANG, Haijun LIU, Renke KANG, Shang GAO

《机械工程前沿（英文）》 2021年第16卷第3期页码 559-569 doi: 10.1007/s11465-020-0624-0

摘要： Taping is often used to protect patterned wafers and reduce fragmentation during backgrinding of silicon wafers. Grinding experiments using coarse and fine resin-bond diamond grinding wheels were performed on silicon wafers with tapes of different thicknesses to investigate the effects of taping on peak-to-valley (PV), surface roughness, and subsurface damage of silicon wafers after grinding. Results showed that taping in backgrinding could provide effective protection for ground wafers from breakage. However, the PV value, surface roughness, and subsurface damage of silicon wafers with taping deteriorated compared with those without taping although the deterioration extents were very limited. The PV value of silicon wafers with taping decreased with increasing mesh size of the grinding wheel and the final thickness. The surface roughness and subsurface damage of silicon wafers with taping decreased with increasing mesh size of grinding wheel but was not affected by removal thickness. We hope the experimental finding could help fully understand the role of taping in backgrinding.

关键词： taping silicon wafer backgrinding subsurface damage surface roughness

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

《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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Recognition of diamond grains on surface of fine diamond grinding wheel

HUO Fengwei, JIN Zhuji, KANG Renke, GUO Dongming, YANG Chun

《机械工程前沿（英文）》 2008年第3卷第3期页码 325-331 doi: 10.1007/s11465-008-0071-9

摘要： The accurate evaluation of grinding wheel surface topography, which is necessary for the investigation of the grinding principle, optimism, modeling, and simulation of a grinding process, significantly depends on the accurate recognition of abrasive grains from the measured wheel surface. A detailed analysis of the grain size distribution characteristics and grain profile wavelength of the fine diamond grinding wheel used for ultra-precision grinding is presented. The requirements of the spatial sampling interval and sampling area for instruments to measure the surface topography of a diamond grinding wheel are discussed. To recognize diamond grains, digital filtering is used to eliminate the high frequency disturbance from the measured 3D digital surface of the grinding wheel, the geometric features of diamond grains are then extracted from the filtered 3D digital surface, and a method based on the grain profile frequency characteristics, diamond grain curvature, and distance between two adjacent diamond grains is proposed. A 3D surface profiler based on scanning white light interferometry is used to measure the 3D surface topography of a #3000 mesh resin bonded diamond grinding wheel, and the diamond grains are then recognized from the 3D digital surface. The experimental result shows that the proposed method is reasonable and effective.

关键词： topography frequency disturbance filtering analysis wavelength

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我国海洋钻机设备发展路径研究

刘健

《中国工程科学》 2020年第22卷第6期页码 40-48 doi: 10.15302/J-SSCAE-2020.06.006

摘要：

我国海洋钻机设备的发展已取得一定成就，浅水海洋钻机基本实现了国内自主研制，但深水钻机设备与国外先进水平相比仍有较大差距，未能全面满足我国深水油田开发的需求。本文从浅水钻机、深水钻机和新型海洋钻机三方面分析了国内外海洋钻机设备的发展现状，总结了我国深水钻机设备技术水平发展情况、与国外先进水平的差距，研判了深水钻机设备国产化亟需突破的关键技术并提出了针对性建议。在进行国内外深水钻机关键技术对比分析的基础上，研究指出我国开展海洋钻机装备攻关应从深水钻机研制的设计、材料、工艺、检测、海上试验等方面突破。为明晰海洋钻机设备的发展路径，研究建议：建立和完善海洋钻机设备的标准规范，分类型、分阶段、分层次实施深水钻机设备的研制，建立集成测试和海上试验基地，加强行业间合作，以创新驱动多样化、系列化、自动化、智能化发展。

关键词：海洋钻机深水钻机设备研制检测海上试验

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Effects of delamination in drilling glass/polyester composite

Mehdi GANJIANI, Majid SAFARABADI, Nabi MEHRI-KHANSARI, Hossein ORUJI

《结构与土木工程前沿（英文）》 2021年第15卷第2期页码 552-567 doi: 10.1007/s11709-021-0699-7

摘要： Considering failures during machinery processes such as drilling, a precautionary analysis involving delamination and the corresponding dissipated energy is required, especially for composite structures. In this context, because of the complexity of both the analysis procedure and experimental test setup, most studies prefer to represent mode I and III interlaminar crack propagation instead of that involving mode II. Therefore, in this study, the effect of mode delamination and corresponding interlaminar crack propagation was considered during the drilling process of multilayered glass/polyester composites using both numerical and experimental approaches. In the experimental procedure, the mechanical properties of the glass/polyester specimens were obtained according to ASTM D3039. In addition, the interlaminar mixed-mode (I/II) loadings were determined using an ARCAN test fixture so that the fracture toughness of glass/polyester could then be identified. The mode II critical strain energy release rate (CSERR) was then obtained using an experimental test performed using an ARCAN fixture and the virtual crack closure technique (VCCT). It was determined that the numerical approach was in accordance with the experiments, and more than 95% of crack propagation could be attributed to mode II compared to the two other modes.

关键词： delamination VCCT ARCAN specimen drilling mode II