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

Rupalika DASH,Kalipada MAITY

《机械工程前沿（英文）》 2015年第10卷第4期页码 424-432 doi: 10.1007/s11465-015-0366-6

摘要：

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

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

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

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

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

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

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Revolution and challenges in machining processing aimed at carbon reduction

《机械工程前沿（英文）》 2024年第19卷第1期 doi: 10.1007/s11465-023-0771-1

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

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

《机械工程前沿（英文）》 2013年第8卷第2期页码 187-200 doi: 10.1007/s11465-013-0262-x

摘要：

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

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

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

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

《机械工程前沿（英文）》 2021年第16卷第2期页码 285-297 doi: 10.1007/s11465-021-0631-9

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

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

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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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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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Optimization of multi machining characteristics in WEDM of WC-5.3%Co composite using integrated approach

Kamal JANGRA, Sandeep GROVER, Aman AGGARWAL

《机械工程前沿（英文）》 2012年第7卷第3期页码 288-299 doi: 10.1007/s11465-012-0333-4

摘要：

Wire electrical discharge machining (WEDM) is a well known process for generating intricate and complex geometries in hard metal alloys and metal matrix composites with high precision. In present work, intricate machining of WC-5.3%Co composite on WEDM has been reported. Taguchi’s design of experiment has been utilised to investigate the process parameters for four machining characteristics namely material removal rate, surface roughness, angular error and radial overcut. In order to optimize the four machining characteristics simultaneously, grey relational analysis (GRA) coupled with entropy measurement method has been employed. Through GRA, grey relational grade has been computed as a performance index for predicting the optimal parameters setting for multi machining characteristics. Using Analysis of Variance (ANOVA) on grey relational grade, significant parameters affecting the multi-machining characteristics has been determined. Confirmatory results prove the potential of present approach.

关键词： tungsten carbide composite wire electrical discharge machining (WEDM) Taguchi method grey relational analysis (GRA) entropy measurement method

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高效加工技术及其应用研究

艾兴

《中国工程科学》 2000年第2卷第11期页码 40-51

摘要：

在机械加工领域，切削加工是应用最广泛的一种加工方法，其发展方向主要是研究髙速切削，对超硬材料加工，主要是发展磨削、超声和放电等高效复合加工技术。文章介绍对髙效切削加工和高效复合加工技术的理论研究和技术开发与应用及所取得的重要成果，主要包括高速切削基础理论、陶瓷刀具材料研究新体系和超硬材料断续磨、超声和电火花的复合加工理论与技术的研究开发。生产实际应用结果表明，高效加工技术可以大幅度提髙加工效率，改善加工表面质量，降低加工成本。

关键词：高效加工技术髙速切削陶瓷刀具材料断续磨-间瞭脉冲放电复合加工超声-间隙脉冲放电复合加工