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A review on ductile mode cutting of brittle materials

Elijah Kwabena ANTWI, Kui LIU, Hao WANG

《机械工程前沿（英文）》 2018年 第13卷 第2期   页码 251-263 doi: 10.1007/s11465-018-0504-z

摘要：

Brittle materials have been widely employed for industrial applications due to their excellent mecha-nical, optical, physical and chemical properties. But obtaining smooth and damage-free surface on brittle materials by traditional machining methods like grinding, lapping and polishing is very costly and extremely time consuming. Ductile mode cutting is a very promising way to achieve high quality and crack-free surfaces of brittle materials. Thus the study of ductile mode cutting of brittle materials has been attracting more and more efforts. This paper provides an overview of ductile mode cutting of brittle materials including ductile nature and plasticity of brittle materials, cutting mechanism, cutting characteristics, molecular dynamic simulation, critical undeformed chip thickness, brittle-ductile transition, subsurface damage, as well as a detailed discussion of ductile mode cutting enhancement. It is believed that ductile mode cutting of brittle materials could be achieved when both crack-free and no subsurface damage are obtained simultaneously.

关键词： ductile mode cutting     brittle materials     critical undeformed chip thickness     brittle-ductile transition     subsurface damage     molecular dynamic simulation    

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Design of ultrasonic elliptical vibration cutting system for tungsten heavy alloy

《机械工程前沿（英文）》 2022年 第17卷 第4期 doi: 10.1007/s11465-022-0715-1

摘要： Nanoscale surface roughness of tungsten heavy alloy components is required in the nuclear industry and precision instruments. In this study, a high-performance ultrasonic elliptical vibration cutting (UEVC) system is developed to solve the precision machining problem of tungsten heavy alloy. A new design method of stepped bending vibration horn based on Timoshenko’s theory is first proposed, and its design process is greatly simplified. The arrangement and working principle of piezoelectric transducers on the ultrasonic vibrator using the fifth resonant mode of bending are analyzed to realize the dual-bending vibration modes. A cutting tool is installed at the end of the ultrasonic vibration unit to output the ultrasonic elliptical vibration locus, which is verified by finite element method. The vibration unit can display different three-degree-of-freedom (3-DOF) UEVC characteristics by adjusting the corresponding position of the unit and workpiece. A dual-channel ultrasonic power supply is developed to excite the ultrasonic vibration unit, which makes the UEVC system present the resonant frequency of 41 kHz and the maximum amplitude of 14.2 μm. Different microtopography and surface roughness are obtained by the cutting experiments of tungsten heavy alloy hemispherical workpiece with the UEVC system, which validates the proposed design’s technical capability and provides optimization basis for further improving the machining quality of the curved surface components of tungsten heavy alloy.

关键词： tungsten heavy alloy     ultrasonic elliptical vibration cutting     Timoshenko’s theory     resonant mode of bending     finite element method    

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Analysis and comparison of laser cutting performance of solar float glass with different scanning modes

Wenyuan LI, Yu HUANG, Youmin RONG, Long CHEN, Guojun ZHANG, Zhangrui GAO

《机械工程前沿（英文）》 2021年 第16卷 第1期   页码 97-110 doi: 10.1007/s11465-020-0600-8

摘要： Cutting quality and efficiency have always been important indicators of glass laser cutting. Laser scanning modes have two kinds, namely, the spiral and concentric circle scanning modes. These modes can achieve high-performance hole cutting of thick solar float glass using a 532-nm nanosecond laser. The mechanism of the glass laser cutting under these two different scanning modes has been described. Several experiments are conducted to explore the effect of machining parameters on cutting efficiency and quality under these two scanning modes. Results indicate that compared with the spiral scanning mode, the minimum area of edge chipping (218340 µm ) and the minimum Ra (3.01 µm) in the concentric circle scanning mode are reduced by 9.4% and 16.4% respectively. Moreover, the best cutting efficiency scanning mode is 14.2% faster than that in the spiral scanning mode. The best parameter combination for the concentric circle scanning mode is as follows: Scanning speed: 2200 mm/s, number of inner circles: 6, and circle spacing: 0.05 mm. This parameter combination reduces the chipping area and sidewall surface roughness by 8.8% and 9.6% respectively at the same cutting efficiency compared with the best spiral processing parameters. The range of glass processing that can be achieved in the concentric circle scanning mode is wider than that in the spiral counterpart. The analyses of surface topography, white spots, microstructures, and sidewall surface element composition are also performed. The study concluded that the concentric circle scanning mode shows evident advantages in the performance of solar float glass hole cutting.

关键词： laser cutting     solar float glass     scanning mode     surface quality     cutting efficiency    

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Mechanical properties of vanadium-alloyed austempered ductile iron for crankshaft applications

《机械工程前沿（英文）》 2023年 第18卷 第3期 doi: 10.1007/s11465-023-0746-2

摘要： This study focused on the development of austempered ductile iron (ADI) with desirable combination of mechanical properties for crankshaft applications by the combined effect of vanadium (V) alloying and an optimized heat treatment process. The produced unalloyed GGG60, 0.15% V-alloyed GGG60 (V-15), and 0.30% V-alloyed GGG60 samples were subjected to austenitizing at 900 °C for 1 h and subsequent austempering processes at 250, 300, and 350 °C for 15, 30, 60, 90, and 180 min. As a result of these austempering processes, different bainitic structures were obtained, which led to the formation of diverse combinations of mechanical properties. The mechanical properties of the austempered samples were tested comprehensively, and the results were correlated with their microstructures and the stability of the retained austenite phases. From the microstructural observations, the V-alloyed samples exhibited a finer microstructure and a more acicular ferrite phase than unalloyed samples. The V addition delayed the coarsening of the acicular ferrite structures and considerably contributed to the improvement of the mechanical properties of GGG60. Moreover, the X-ray diffraction results revealed that the retained austenite volume and the carbon enrichment of austenite phases in ADI samples were remarkably affected by the addition of vanadium. The increase in volume fraction of retained austenite and its carbon content provided favorable ductility and toughness to V-15, as confirmed by the elongation and impact test results. Consequently, the dual-phase ausferrite microstructure of V-15 that was austempered at 300 °C for 60 min exhibited high strength with substantial ductility and toughness for crankshaft applications.

关键词： austempered ductile iron (ADI)     vanadium alloying     mechanical properties     crankshafts     retained austenite    

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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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双轮铣槽机铣削系统自适应模糊积分滑模转速控制

Qi-yan Tian, Jian-hua Wei, Jin-hui Fang, Kai Guo,jhfang@zju.edu.cn

《信息与电子工程前沿（英文）》 2016年 第17卷 第1期   页码 55-66 doi: 10.1631/FITEE.15a0160

摘要： 目的：随着地下连续墙施工工法和双轮铣槽机技术不断发展，实现对双轮铣槽机铣削系统铣轮工作转速的快速精确控制具有重要意义。在负载特性未知、扰动复杂的情况下，本文基于自适应模糊积分滑模（AFISMC）控制算法，实现对铣削系统铣轮转速的良好控制。 创新点：在双轮铣槽机铣轮铣削过程中，铣轮转速控制受到岩石和土壤未知负载特性的影响，同时地质条件不断变化。由于岩石和土壤复杂的负载特性，铣轮的切削扭矩与地质条件、铣轮进给速度等均存在耦合关系，而且其动态特性复杂未知，无法建立准确的数学模型。本文针对以上难点，设计新型自适应模糊积分滑模转速控制器。 方法：针对双轮铣槽机铣削系统的特性，提出一种基于自适应模糊积分滑模控制（AFISMC）的铣轮转速控制方案。该控制方案将自适应控制的参数自整定特性、积分滑模控制的鲁棒性以及模糊系统独立于数学模型的特性结合起来。通过自适应模糊系统对被控对象未知模型有效逼近，使用反步法对控制器进行设计，采用Lyapunov理论证明整个闭环系统（包括自适应模糊推理系统、积分滑模控制器和被控对象）的稳定性。 结论：在双轮铣槽机液压模拟实验台对不同工况下的铣轮转速控制进行实验，分别采用PI、ISMC和AFISMC三种控制方法进行对比。实验结果表明AFISMC控制算法在跟踪和抗干扰方面均表现出良好的控制性能。

关键词： 铣削系统；电液系统；铣削转速控制；自适应模糊积分滑模控制    

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Influence of welding residual stresses on the ductile crack growth resistance of circumferentially cracked

Xiaobo REN, Odd M. AKSELSEN, B?rd NYHUS, Zhiliang ZHANG

《结构与土木工程前沿（英文）》 2012年 第6卷 第3期   页码 217-223 doi: 10.1007/s11709-012-0169-3

摘要： Welding residual stress is one of the main concerns for fabrication and operation of steel structures due to its potential effect on structural integrity. This paper focuses on the effect of welding residual stress on the ductile crack growth resistance of circumferentially cracked steel pipes. Two-dimensional axi-symmetry model has been used to simulate the pipe. Residual stresses were introduced into the model by using so-called eigenstrain method. The complete Gurson model has been employed to calculate the ductile crack growth resistance. Results show that residual stresses reduce the ductile crack growth resistance. However, the effect of residual stresses on ductile crack growth resistance decreases with the increase of crack growth. The effect of residual stress has also been investigated for cases with different initial void volume fraction, material hardening and crack sizes.

关键词： residual stress     ductile crack growth resistance     complete Gurson model     eigenstrain method    

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Ductile extension of 3-D external circumferential cracks in pipe structures

Wuchao YANG, Xudong QIAN

《结构与土木工程前沿（英文）》 2011年 第5卷 第3期   页码 294-303 doi: 10.1007/s11709-011-0115-9

摘要： This study investigates the ductile fracture resistance of 3-D external circumferential cracks in the wall of a steel pipe under remote tension, using a damage-mechanism model originally proposed by Gurson and Tvergaard. The ductile crack extension utilizes an element extinction technique implemented in the computational cell framework. The key parameter for the computational cell method, i.e., the initial porosity ratio , is calibrated using both the fracture resistance and the load-deformation responses obtained from fracture tests of multiple single-edge bend [SE(B)] specimens made of high-strength steel, HY80, which has a yield strength of 630 MPa. The fracture resistance along the 3-D semi-elliptical crack front is computed from the calibrated cell model. Based on the similarity concept in the near-tip stress-strain fields, this study demonstrates that an equivalent 2-D axi-symmetric model provides conservative estimations of the fracture resistance for 3-D circumferential cracks in pipes.

关键词： ductile fracture     computational cell method     G-T model     J-R curve    

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Crystallographic orientation effect on cutting-based single atomic layer removal

Wenkun XIE, Fengzhou FANG

《机械工程前沿（英文）》 2020年 第15卷 第4期   页码 631-644 doi: 10.1007/s11465-020-0599-x

摘要： The ever-increasing requirements for the scalable manufacturing of atomic-scale devices emphasize the significance of developing atomic-scale manufacturing technology. The mechanism of a single atomic layer removal in cutting is the key basic theoretical foundation for atomic-scale mechanical cutting. Material anisotropy is among the key decisive factors that could not be neglected in cutting at such a scale. In the present study, the crystallographic orientation effect on the cutting-based single atomic layer removal of monocrystalline copper is investigated by molecular dynamics simulation. When undeformed chip thickness is in the atomic scale, two kinds of single atomic layer removal mechanisms exist in cutting-based single atomic layer removal, namely, dislocation motion and extrusion, due to the differing atomic structures on different crystallographic planes. On close-packed crystallographic plane, the material removal is dominated by the shear stress-driven dislocation motion, whereas on non-close packed crystallographic planes, extrusion-dominated material removal dominates. To obtain an atomic, defect-free processed surface, the cutting needs to be conducted on the close-packed crystallographic planes of monocrystalline copper.

关键词： ACSM     single atomic layer removal mechanism     crystallographic orientation effect     mechanical cutting     Manufacturing III    

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Ultra-precision ductile grinding of BK7 using super abrasive diamond wheel

ZHAO Qingliang, Brinksmeier Ekkard, Riemer Oltmann, Rickens Kai

《机械工程前沿（英文）》 2007年 第2卷 第3期   页码 350-355 doi: 10.1007/s11465-007-0061-3

摘要： In this paper, a novel conditioning technique using copper bonded diamond grinding wheels of 91 yD grain size and electrolytic in-process dressing (ELID) is first developed to precisely and effectively condition a nickel-electroplated monolayer coarse-grained diamond grinding wheel of 151 μm grain size. Under optimised conditioning parameters, the super abrasive diamond wheel was well conditioned in terms of a minimized run-out error and flattened diamond grain surfaces of constant peripheral envelope. The conditioning force was monitored by a force transducer, while the modified wheel surface status was in-situ monitored by a coaxial optical distance measurement system. Finally, the grinding experiment on BK7 was conducted using the well-conditioned wheel with the corresponding surface morphology and subsurface damage measured by atomic force microscope (AFM) and scanning electric microscope (SEM), respectively. The experimental result shows that the newly developed conditioning technique is applicable and feasible to ductile grinding optical glass featuring nano scale surface roughness, indicating the potential of super abrasive diamond wheels in ductile machining brittle materials.

关键词： ELID     peripheral     electrolytic in-process     nickel-electroplated monolayer     measurement    

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Modeling of the minimum cutting thickness in micro cutting with consideration of the friction aroundthe cutting zone

Tianfeng ZHOU, Ying WANG, Benshuai RUAN, Zhiqiang LIANG, Xibin WANG

《机械工程前沿（英文）》 2020年 第15卷 第1期   页码 81-88 doi: 10.1007/s11465-019-0561-y

摘要： Friction modeling between the tool and the workpiece plays an important role in predicting the minimum cutting thickness during TC4 micro machining and finite element method (FEM) cutting simulation. In this study, a new three-region friction modeling is proposed to illustrate the material flow mechanism around the friction zone in micro cutting; estimate the stress distributions on the rake, edge, and clearance faces of the tool; and predict the stagnation point location and the minimum cutting thickness. The friction modeling is established by determining the distribution of normal and shear stress. Then, it is applied to calculate the stagnation point location on the edge face and predict the minimum cutting thickness. The stagnation point and the minimum cutting thickness are also observed and illustrated in the FEM simulation. Micro cutting experiments are conducted to validate the accuracy of the friction and the minimum cutting thickness modeling. Comparison results show that the proposed friction model illustrates the relationship between the normal and sheer stress on the tool surface, thereby validating the modeling method of the minimum cutting thickness in micro cutting.

关键词： tool friction     minimum cutting thickness     finite element method     tool edge radius     micro cutting    

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Cutting performance of surgical electrodes by constructing bionic microstriped structures

《机械工程前沿（英文）》 2023年 第18卷 第1期 doi: 10.1007/s11465-022-0728-9

摘要： Surgical electrodes rely on thermal effect of high-frequency current and are a widely used medical tool for cutting and coagulating biological tissue. However, tissue adhesion on the electrode surface and thermal injury to adjacent tissue are serious problems in surgery that can affect cutting performance. A bionic microstriped structure mimicking a banana leaf was constructed on the electrode via nanosecond laser surface texturing, followed by silanization treatment, to enhance lyophobicity. The effect of initial, simple grid-textured, and bionic electrodes with different wettabilities on tissue adhesion and thermal injury were investigated using horizontal and vertical cutting modes. Results showed that the bionic electrode with high lyophobicity can effectively reduce tissue adhesion mass and thermal injury depth/area compared with the initial electrode. The formation mechanism of adhered tissue was discussed in terms of morphological features, and the potential mechanism for antiadhesion and heat dissipation of the bionic electrode was revealed. Furthermore, we evaluated the influence of groove depth on tissue adhesion and thermal injury and then verified the antiadhesion stability of the bionic electrode. This study demonstrates a promising approach for improving the cutting performance of surgical electrodes.

关键词： surgical electrodes     tissue adhesion     thermal injury     bionic structures     cutting performance     medical tools    

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Edge preparation methods for cutting tools: a review

《机械工程前沿（英文）》 2023年 第18卷 第4期 doi: 10.1007/s11465-023-0766-y

摘要： Edge preparation can remove cutting edge defects, such as burrs, chippings, and grinding marks, generated in the grinding process and improve the cutting performance and service life of tools. Various edge preparation methods have been proposed for different tool matrix materials, geometries, and application requirements. This study presents a scientific and systematic review of the development of tool edge preparation technology and provides ideas for its future development. First, typical edge characterization methods, which associate the microgeometric characteristics of the cutting edge with cutting performance, are briefly introduced. Then, edge preparation methods for cutting tools, in which materials at the cutting edge area are removed to decrease defects and obtain a suitable microgeometry of the cutting edge for machining, are discussed. New edge preparation methods are explored on the basis of existing processing technologies, and the principles, advantages, and limitations of these methods are systematically summarized and analyzed. Edge preparation methods are classified into two categories: mechanical processing methods and nontraditional processing methods. These methods are compared from the aspects of edge consistency, surface quality, efficiency, processing difficulty, machining cost, and general availability. In this manner, a more intuitive understanding of the characteristics can be gained. Finally, the future development direction of tool edge preparation technology is prospected.

关键词： edge preparation method     preparation principle     cutting edge geometry     edge characterization     tool performance    

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Enhanced empirical models for predicting the drift capacity of less ductile RC columns with flexural,

Mohammad Reza AZADI KAKAVAND, Reza ALLAHVIRDIZADEH

《结构与土木工程前沿（英文）》 2019年 第13卷 第5期   页码 1251-1270 doi: 10.1007/s11709-019-0554-2

摘要： Capacity of components subjected to earthquake actions is still a widely interesting research topic. Hence, developing precise tools for predicting drift capacities of reinforced concrete (RC) columns is of great interest. RC columns are not only frequently constructed, but also their composite behavior makes the capacity prediction a task faced with many uncertainties. In the current article, novel empirical approaches are presented for predicting flexural, shear and axial failure modes in RC columns. To this aim, an extensive experimental database was created by collecting outcomes of previously conducted experimental tests since 1964, which are available in the literature. It serves as the basis for deriving the equations for predicting the drift capacity of RC columns by different regression analyses (both linear with different orders and nonlinear). Furthermore, fragility curves are determined for comparing the obtained results with the experimental results and with previously proposed models, like the ones of ASCE/SEI 41-13. It is demonstrated that the proposed equations predict drift capacities, which are in better agreement with experimental results than those computed by previously published models. In addition, the reliability of the proposed equations is higher from a probabilistic point of view.

关键词： flexural-shear-axial failure     drift capacity     reinforced concrete columns     statistical analysis     fragility curves    

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Postprocessor development for ultrasonic cutting of honeycomb core curved surface with a straight blade

《机械工程前沿（英文）》 2023年 第18卷 第1期 doi: 10.1007/s11465-022-0729-8

摘要： When ultrasonically cutting honeycomb core curved parts, the tool face of the straight blade must be along the curved surface’s tangent direction at all times to ensure high-quality machining of the curved surface. However, given that the straight blade is a nonstandard tool, the existing computer-aided manufacturing technology cannot directly realize the above action requirement. To solve this problem, this paper proposed an algorithm for extracting a straight blade real-time tool face vector from a 5-axis milling automatically programmed tool location file, which can realize the tool location point and tool axis vector conversion from the flat end mill to the straight blade. At the same time, for the multi-solution problem of the rotation axis, the dependent axis rotation minimization algorithm was introduced, and the spindle rotation algorithm was proposed for the tool edge orientation problem when the straight blade is used to machine the curved part. Finally, on the basis of the MATLAB platform, the dependent axis rotation minimization algorithm and spindle rotation algorithm were integrated and compiled, and the straight blade ultrasonic cutting honeycomb core postprocessor was then developed. The model of the machine tool and the definition of the straight blade were conducted in the VERICUT simulation software, and the simulation machining of the equivalent entity of the honeycomb core can then be realized. The correctness of the numerical control program generated by the postprocessor was verified by machining and accuracy testing of the two designed features. Observation and analysis of the simulation and experiment indicate that the tool pose is the same under each working condition, and the workpieces obtained by machining also meet the corresponding accuracy requirements. Therefore, the postprocessor developed in this paper can be well adapted to the honeycomb core ultrasonic cutting machine tool and realize high-quality and high-efficient machining of honeycomb core composites.

关键词： honeycomb core     straight blade     ultrasonic cutting     tool pose     postprocessor    

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标题 作者 时间 类型 操作

A review on ductile mode cutting of brittle materials

Elijah Kwabena ANTWI, Kui LIU, Hao WANG

期刊论文

Design of ultrasonic elliptical vibration cutting system for tungsten heavy alloy

期刊论文

Analysis and comparison of laser cutting performance of solar float glass with different scanning modes

Wenyuan LI, Yu HUANG, Youmin RONG, Long CHEN, Guojun ZHANG, Zhangrui GAO

期刊论文

Mechanical properties of vanadium-alloyed austempered ductile iron for crankshaft applications

期刊论文

Experimental research on ductile fracture criterion in metal forming

Song YU, Weiming FENG

期刊论文

双轮铣槽机铣削系统自适应模糊积分滑模转速控制

Qi-yan Tian, Jian-hua Wei, Jin-hui Fang, Kai Guo,jhfang@zju.edu.cn

期刊论文

Influence of welding residual stresses on the ductile crack growth resistance of circumferentially cracked

Xiaobo REN, Odd M. AKSELSEN, B?rd NYHUS, Zhiliang ZHANG

期刊论文

Ductile extension of 3-D external circumferential cracks in pipe structures

Wuchao YANG, Xudong QIAN

期刊论文

Crystallographic orientation effect on cutting-based single atomic layer removal

Wenkun XIE, Fengzhou FANG

期刊论文

Ultra-precision ductile grinding of BK7 using super abrasive diamond wheel

ZHAO Qingliang, Brinksmeier Ekkard, Riemer Oltmann, Rickens Kai

期刊论文

Modeling of the minimum cutting thickness in micro cutting with consideration of the friction aroundthe cutting zone

Tianfeng ZHOU, Ying WANG, Benshuai RUAN, Zhiqiang LIANG, Xibin WANG

期刊论文

Cutting performance of surgical electrodes by constructing bionic microstriped structures

期刊论文

Edge preparation methods for cutting tools: a review

期刊论文

Enhanced empirical models for predicting the drift capacity of less ductile RC columns with flexural,

Mohammad Reza AZADI KAKAVAND, Reza ALLAHVIRDIZADEH

期刊论文

Postprocessor development for ultrasonic cutting of honeycomb core curved surface with a straight blade

期刊论文