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optimization of process parameters in Electro-Discharge Diamond Face Grinding based on ANN-NSGA-II hybrid

Ravindra Nath YADAV, Vinod YADAVA, G.K. SINGH

《机械工程前沿（英文）》 2013年 第8卷 第3期   页码 319-332 doi: 10.1007/s11465-013-0269-3

摘要：

The effective study of hybrid machining processes (HMPs), in terms of modeling and optimization has always been a challenge to the researchers. The combined approach of Artificial Neural Network (ANN) and Non-Dominated Sorting Genetic Algorithm-II (NSGA-II) has attracted attention of researchers for modeling and optimization of the complex machining processes. In this paper, a hybrid machining process of Electrical Discharge Face Grinding (EDFG) and Diamond Face Grinding (DFG) named as Electrical Discharge Diamond face Grinding (EDDFG) have been studied using a hybrid methodology of ANN-NSGA-II. In this study, ANN has been used for modeling while NSGA-II is used to optimize the control parameters of the EDDFG process. For observations of input-output relations, the experiments were conducted on a self developed face grinding setup, which is attached with the ram of EDM machine. During experimentation, the wheel speed, pulse current, pulse on-time and duty factor are taken as input parameters while output parameters are material removal rate (MRR) and average surface roughness (Ra). The results have shown that the developed ANN model is capable to predict the output responses within the acceptable limit for a given set of input parameters. It has also been found that hybrid approach of ANN-NSGA-II gives a set of optimal solutions for getting appropriate value of outputs with multiple objectives.

关键词： hybrid machining processes (HMPs)     electrical discharge diamond grinding (EDDG)     artificial neural network (ANN)     genetic algorithm     modeling and optimization    

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Pressure swing adsorption/membrane hybrid processes for hydrogen purification with a high recovery

Baojun Li,Gaohong He,Xiaobin Jiang,Yan Dai,Xuehua Ruan

《化学科学与工程前沿（英文）》 2016年 第10卷 第2期   页码 255-264 doi: 10.1007/s11705-016-1567-1

摘要： Hydrogen was recovered and purified from coal gasification-produced syngas using two kinds of hybrid processes: a pressure swing adsorption (PSA)-membrane system (a PSA unit followed by a membrane separation unit) and a membrane-PSA system (a membrane separation unit followed by a PSA unit). The PSA operational parameters were adjusted to control the product purity and the membrane operational parameters were adjusted to control the hydrogen recovery so that both a pure hydrogen product (>99.9%) and a high recovery (>90%) were obtained simultaneously. The hybrid hydrogen purification processes were simulated using HYSYS and the processes were evaluated in terms of hydrogen product purity and hydrogen recovery. For comparison, a PSA process and a membrane separation process were also used individually for hydrogen purification. Neither process alone produced high purity hydrogen with a high recovery. The PSA-membrane hybrid process produced hydrogen that was 99.98% pure with a recovery of 91.71%, whereas the membrane-PSA hybrid process produced hydrogen that was 99.99% pure with a recovery of 91.71%. The PSA-membrane hybrid process achieved higher total H recoveries than the membrane-PSA hybrid process under the same H recovery of membrane separation unit. Meanwhile, the membrane-PSA hybrid process achieved a higher total H recovery (97.06%) than PSA-membrane hybrid process (94.35%) at the same H concentration of PSA feed gas (62.57%).

关键词： hydrogen purification     PSA     membrane separation     hybrid process    

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Inverse kinematics analysis and numerical control experiment for PRS-XY style hybrid machining tool

JIA Dongyong, ZHANG Jianmin, SUN Hongchang, NIU Zhigang

《机械工程前沿（英文）》 2007年 第2卷 第2期   页码 235-238 doi: 10.1007/s11465-007-0041-7

摘要： This paper analyzed the inverse kinematics for the new Parallel rotate slider- axes (PRS-) style hybrid machining tool and educed the five axes linkage inverse kinematics transform formula on the basis of the coordinates of the and virtual axes. The program for the PRS-XY style hybrid machining tool in accordance with the program manner for the common numerical control (NC) machine tool was made. The results of the experiments prove that the inverse kinematics transform formula is correct.

关键词： numerical     accordance     transform formula     virtual     slider-    

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Membrane bioreactors for hospital wastewater treatment: recent advancements in membranes and processes

《化学科学与工程前沿（英文）》 2022年 第16卷 第5期   页码 634-660 doi: 10.1007/s11705-021-2107-1

摘要： Discharged hospital wastewater contains various pathogenic microorganisms, antibiotic groups, toxic organic compounds, radioactive elements, and ionic pollutants. These contaminants harm the environment and human health causing the spread of disease. Thus, effective treatment of hospital wastewater is an urgent task for sustainable development. Membranes, with controllable porous and nonporous structures, have been rapidly developed for molecular separations. In particular, membrane bioreactor (MBR) technology demonstrated high removal efficiency toward organic compounds and low waste sludge production. To further enhance the separation efficiency and achieve material recovery from hospital waste streams, novel concepts of MBRs and their applications are rapidly evolved through hybridizing novel membranes (non hydrophilic ultrafiltration/microfiltration) into the MBR units (hybrid MBRs) or the MBR as a pretreatment step and integrating other membrane processes as subsequent secondary purification step (integrated MBR-membrane systems). However, there is a lack of reviews on the latest advancement in MBR technologies for hospital wastewater treatment, and analysis on its major challenges and future trends. This review started with an overview of main pollutants in common hospital wastewater, followed by an understanding on the key performance indicators/criteria in MBR membranes (i.e., solute selectivity) and processes (e.g., fouling). Then, an in-depth analysis was provided into the recent development of hybrid MBR and integrated MBR-membrane system concepts, and applications correlated with wastewater sources, with a particular focus on hospital wastewaters. It is anticipated that this review will shed light on the knowledge gaps in the field, highlighting the potential contribution of hybrid MBRs and integrated MBR-membrane systems toward global epidemic prevention.

关键词： membrane technology     membrane bioreactor     hospital wastewater     hybrid MBR     integrated MBR-membrane system    

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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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Emerging electrochemical processes for materials recovery from wastewater: Mechanisms and prospects

Lingchen Kong, Xitong Liu

《环境科学与工程前沿（英文）》 2020年 第14卷 第5期 doi: 10.1007/s11783-020-1269-2

摘要： Abstract • Mechanisms for selective recovery of materials in electrochemical processes are discussed. • Wastewaters that contain recoverable materials are reviewed. • Application prospects are discussed from both technical and non-technical aspects. Recovering valuable materials from waste streams is critical to the transition to a circular economy with reduced environmental damages caused by resource extraction activities. Municipal and industrial wastewaters contain a variety of materials, such as nutrients (nitrogen and phosphorus), lithium, and rare earth elements, which can be recovered as value-added products. Owing to their modularity, convenient operation and control, and the non-requirement of chemical dosage, electrochemical technologies offer a great promise for resource recovery in small-scale, decentralized systems. Here, we review three emerging electrochemical technologies for materials recovery applications: electrosorption based on carbonaceous and intercalation electrodes, electrochemical redox processes, and electrochemically induced precipitation. We highlight the mechanisms for achieving selective materials recovery in these processes. We also present an overview of the advantages and limitations of these technologies, as well as the key challenges that need to be overcome for their deployment in real-world systems to achieve cost-effective and sustainable materials recovery.

关键词： Materials recovery     Electrosorption     Capacitive deionization     Redox processes     Electrochemical precipitation    

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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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标题 作者 时间 类型 操作

optimization of process parameters in Electro-Discharge Diamond Face Grinding based on ANN-NSGA-II hybrid

Ravindra Nath YADAV, Vinod YADAVA, G.K. SINGH

期刊论文

Pressure swing adsorption/membrane hybrid processes for hydrogen purification with a high recovery

Baojun Li,Gaohong He,Xiaobin Jiang,Yan Dai,Xuehua Ruan

期刊论文

Inverse kinematics analysis and numerical control experiment for PRS-XY style hybrid machining tool

JIA Dongyong, ZHANG Jianmin, SUN Hongchang, NIU Zhigang

期刊论文

Membrane bioreactors for hospital wastewater treatment: recent advancements in membranes and processes

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

Emerging electrochemical processes for materials recovery from wastewater: Mechanisms and prospects

Lingchen Kong, Xitong Liu

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