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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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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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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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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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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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WEIS wheel speed real-time measuring method for VOSM

Mengyao PAN, Guixiong LIU, Xiaobin HONG, Tusheng LIN,

《机械工程前沿（英文）》 2010年第5卷第3期页码 322-327 doi: 10.1007/s11465-010-0022-0

摘要： Wheel speed is one of the key parameters of vehicle operating attitude. To solve the problems in traditional wheel speed measuring methods, such as low measurement precision and the lack of real-time monitoring of the vehicle’s operating attitude, a wheel embedded intelligent sensors (WEIS) wheel speed measuring method for vehicle operating safety states monitoring (VOSM) is innovatively proposed. Radial acceleration signal is obtained through a WEIS module embedded in the hub. Using wavelet packet to implement wavelet de-noising for the non-stationary acceleration signals, and adopting short-time Fourier transform (STFT) algorithm to extract the signal characteristics, the wheel speed measurement can be achieved. The experimental result shows that under experimental conditions the speed measurement error is −2.05%, and the speed measuring response time is 0.45 s.

关键词： wheel embedded intelligent sensing wheel speed monitoring

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Fatigue and impact analysis and multi-objective optimization design of Mg/Al assembled wheel considering

《机械工程前沿（英文）》 2022年第17卷第3期 doi: 10.1007/s11465-022-0701-7

摘要： The multi-material assembled light alloy wheel presents an effective lightweight solution for new energy vehicles, but its riveting connection remains a problem. To address this problem, this paper proposed the explicit riveting-implicit springback-implicit fatigue/explicit impact sequence coupling simulation analysis method, analyzed the fatigue and impact performance of the punching riveting connected magnesium/aluminum alloy (Mg/Al) assembled wheel, and constructed some major evaluation indicators. The accuracy of the proposed simulation method was verified by conducting physical experiments of single and cross lap joints. The punching riveting process parameters of the assembled wheel joints were defined as design variables, and the fatigue and impact performance of the assembled wheel was defined as the optimization objective. The connection-performance integration multi-objective optimization design of the assembled wheel considering riveting residual stress was designed via Taguchi experiment, grey relational analysis, analytic hierarchy process, principal component analysis, and entropy weighting methods. The optimization results of the three weighting methods were compared, and the optimal combination of design variables was determined. The fatigue and impact performance of the Mg/Al assembled wheel were effectively improved after optimization.

关键词： magnesium/aluminum assembled wheel riveting residual stress fatigue analysis impact analysis multi-objective optimization

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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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Lightening structure optimization on turbine wheel of vehicular turbocharger

ZHAO Junsheng, MA Chaochen, HU Liaoping

《能源前沿（英文）》 2008年第2卷第4期页码 422-426 doi: 10.1007/s11708-008-0098-y

摘要： Based on basic principle of optimization design, structure optimization of turbine is conducted using optimization module of ANSYS and APDL in order to get the minimum turbine weight. Meanwhile, the original blade profile and flow passage are maintained, and the structural strength of the turbine are guaranteed. Considering assembly technique and cast requirement, the structure of the modified turbine is determined which can save 6.91 percent of the material compared with the original one. The modified turbine not only saved material, but also gained better effect of mass distribution between the turbine and the compressor impeller. The result can provide useful reference to engineering application of turbocharger.

关键词： requirement technique engineering application turbocharger reference

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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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Numerical simulation and experimental research on the wheel brush sampling process of an asteroid sampler

《机械工程前沿（英文）》 2023年第18卷第2期 doi: 10.1007/s11465-022-0732-0

摘要： To examine the environmental characteristics of the microgravity force and the weathered layer on an asteroid surface, a symmetric wheel brush asteroid sampler is proposed for the collection of particles on the asteroid surface. To study the influence of the wheel brush rotation speed on the sampling efficiency and the driving torque required for the wheel brush, the contact dynamics model between particles and sampling wheel brushes is established and a simulation and experimental verification of the sampling process are conducted. The parameter calibration of the sampled particles is studied first, and the calibrated particle parameters are used in the numerical simulation of the sampling process. The sampling results and the particle stream curves are obtained for the working conditions of different rotation speeds, and the effects of different parameter settings on the sampling efficiency are analyzed. In addition, a set of rotating symmetrical sampling wheel brush devices is built for the ground test, and the dynamic torque sensor is used to test the torque change of the wheel brush during the sampling process. The relationship between the speed of the wheel brush and the driving torque of the wheel brush motor is determined by comparing the simulation results with the test results. Results indicate that when the rotating speed of the wheel brush is faster, the sampling efficiency is higher, and the driving torque required for the sampling wheel brush is greater. Moreover, a numerical simulation analysis of the sampling process of the wheel brush sampler in a microgravity environment is conducted to determine the optimal speed condition, and the brushing test of the wheel brush sampler in the microgravity environment is verified with the drop tower method. This research proposes the structural optimization design and motor selection of a wheel brush asteroid sampler, which provides important reference value and engineering significance.

关键词： asteroid sampling wheel brush sampler discrete element method parameter calibration experimental research