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增材制造 4

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激光去除与连接技术发展研究

陈俐,巩水利,何恩光

《中国工程科学》 2020年第22卷第3期页码 78-84 doi: 10.15302/J-SSCAE-2020.03.012

摘要：

随着激光技术的发展，激光去除与连接技术深刻影响着制造业技术的发展，并以柔性、高效、高质的综合优势成为不可或缺的先进制造技术。在先进制造智能化发展的时代，激光技术、数字信息技术等的融合必将推动激光去除与连接技术的应用发展与创新。本文选取工业应用最广的激光焊接、激光切割、激光打孔、激光打标4 种激光去除与连接技术，概述了激光去除与连接技术的应用现状，分析了其在支撑先进制造发展过程中存在的问题。研究表明，激光去除与连接技术的发展应注重工艺基础和装备研究一体化的研究，解决激光加工单元部件、激光加工工艺、智能集成各环节的关键技术，强化工艺基础研究平台建设，关注技术创新和人才培养的多维度结合，以促进激光去除与连接技术从工艺应用开发到装备市场保障的生态链式的协同发展。

关键词：激光加工激光焊接激光切割激光打孔激光打标

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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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Dimethicone-aided laser cutting of solar rolled glass

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

《机械工程前沿（英文）》 2021年第16卷第1期页码 111-121 doi: 10.1007/s11465-020-0615-1

摘要： Solar rolled glass, with one micro-structure surface and another roughness surface, can cause diffuse refraction of the focused laser spot, and this phenomenon restricts the application of laser manufacturing. In this study, laser cutting of solar rolled glass with a thickness of 2.5 mm was successfully achieved with the help of dimethicone to ensure laser focusing. Dimethicone was coated on the top surface of the rolled glass processing zone, and a bottom–up multilayer increment with the spiral line was applied to control the cutting path. Different viscosity values of dimethicone were considered. Results showed that surface quality increased as the viscosity increased until a certain threshold was reached; afterward, the surface quality decreased or directly caused the cutting to fail. The minimum surface roughness (3.26 µm) of the processed surface (chipping: Width≤113.64 µm, area 215199 µm ) was obtained when the dimethicone viscosity and laser pulse frequency were 1000 mm /s and 43 kHz (power 25.4 W), respectively. The micro-defects on the processed surface were few, and the edge chipping width and depth of the laser processed surface were small.

关键词： laser cutting solar rolled glass dimethicone viscosity surface quality

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激光热应力切割玻璃实验与分析

殷苏民,张雷洪,许仁军,张凌峰,葛涛

《中国工程科学》 2007年第9卷第3期页码 67-70

摘要：

CO₂激光器平均输出功率为100W时，通过聚焦光路在玻璃表面形成圆型的聚焦点。玻璃强烈地吸收10.6μm的激光，激光能量被玻璃表面15μm厚的吸收层吸收，形成局部的应力纹样分布（设定的切割线）。介绍了淬火气嘴将冷空气吹到玻璃表面对受热区域进行快速淬火；100W的激光能量照射玻璃表面，产生高于玻璃软化的温度；吹气冷却形成应力集中的热应力层，使玻璃从切开的断口沿切割线断开，断口光洁。实验证明，激光热应力切割玻璃的最佳速度是400mm/s。

关键词：激光玻璃热应力切割

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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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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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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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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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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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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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Improved analytical model for residual stress prediction in orthogonal cutting

null

《机械工程前沿（英文）》 2014年第9卷第3期页码 249-256 doi: 10.1007/s11465-014-0310-1

摘要：

The analytical model of residual stress in orthogonal cutting proposed by Jiann is an important tool for residual stress prediction in orthogonal cutting. In application of the model, a problem of low precision of the surface residual stress prediction is found. By theoretical analysis, several shortages of Jiann’s model are picked out, including: inappropriate boundary conditions, unreasonable calculation method of thermal stress, ignorance of stress constraint and cyclic loading algorithm. These shortages may directly lead to the low precision of the surface residual stress prediction. To eliminate these shortages and make the prediction more accurate, an improved model is proposed. In this model, a new contact boundary condition between tool and workpiece is used to make it in accord with the real cutting process; an improved calculation method of thermal stress is adopted; a stress constraint is added according to the volume-constancy of plastic deformation; and the accumulative effect of the stresses during cyclic loading is considered. At last, an experiment for measuring residual stress in cutting AISI 1045 steel is conducted. Also, Jiann’s model and the improved model are simulated under the same conditions with cutting experiment. The comparisons show that the surface residual stresses predicted by the improved model is closer to the experimental results than the results predicted by Jiann’s model.

关键词： residual stress analytical model orthogonal cutting cutting force cutting temperature

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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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Depth of cut models for multipass abrasive waterjet cutting of alumina ceramics with nozzle oscillation

Jun WANG

《机械工程前沿（英文）》 2010年第5卷第1期页码 19-32 doi: 10.1007/s11465-009-0082-1

摘要： An experimental study of the depth of cut in multipass abrasive waterjet (AWJ) cutting of alumina ceramics with controlled nozzle oscillation is presented. It is found that this cutting technique can significantly increase the depth of cut by an average of 50.8% as compared to single pass cutting without nozzle oscillation under the corresponding cutting conditions and within the same cutting time. Predictive models for the depth of cut are then developed. The modelling process starts with single pass cutting using a dimensional analysis technique and the particle erosion theories applied to alumina ceramics, before progressing to the development of the models for multipass cutting. The models are finally assessed both qualitatively and quantitatively with experimental data. It is shown that the model predictions are in good agreement with the experimental data with the average deviations of about 1%.

关键词： abrasive waterjet engineering ceramics depth of cut cutting performance nozzle oscillation machining

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Temperature field simulation of laser homogenizing equipment

Juanjuan WANG, Yunshan WANG, Fudong ZHU

《机械工程前沿（英文）》 2009年第4卷第1期页码 49-52 doi: 10.1007/s11465-009-0005-1

摘要： The laser homogenizing equipment was devised using the ring scanning principle. Its working principle is explained. A laser scanning ring facula is obtained when the laser beam goes through the equipment’s optical system rotating with high-frequency. The scanning ring facula’s mathematic model is established based on the temperature field’s superposing principle. The ring facula’s light intensity distribution and temperature distribution characteristics are achieved by simulating its temperature field. By studying the effect of parameters on the temperature field, the best parameter can be found. Results show that favorable temperature distribution characteristics can be attained by choosing appropriate parameters, and even the thermal effect can be realized by utilizing the circumference power compensating for the heat exchange lost in the horizontal direction. The uniform hardness layer and better process quality can be attained using the ring facula optimized for metal laser heat treatment.

关键词： laser homogenizing technology laser scanning ring facula temperature field