原子级制造的关键基础科学问题

人类的制造技术逐步向原子级推进,原子作为化学反应中的最小粒子,虽然它可以分成更小的原子核、电子等,但是从制造的角度看,原子级制造可以说是人类制造的最底层技术,也是继微纳制造之后新的制造范式,可将制造精度以及产品性能推向极致水平,代表着人类对物质世界认知和制造能力发展的新阶段,是引领未来产业变革发展的战略性技术,也是保障国家安全和推动国计民生重大装备跨代升级的重要前沿方向。本文基于第330期双清论坛总结了原子级制造的研究现状、发展趋势及机遇挑战,凝练出未来5~10年原子级制造的焦点问题和亟需解决的关键科学问题,探讨了相关领域的前沿发展方向和科学基金资助战略。

Machining the Integral Impeller and Blisk of Aero-Engines:A Review of Surface Finishing and Strengthening Technologies

The integral impeller and blisk of an aero-engine are high performance parts with complex structure and made of difficult-to-cut materials. The blade surfaces of the integral impeller and blisk are functional surfaces for power transmission, and their surface integrity has signif- icant effects on the aerodynamic efficiency and service life of an aero-engine. Thus, it is indispensable to finish and strengthen the blades before use. This paper presents a comprehensive literature review of studies on finishing and strengthening technologies for the impeller and blisk of aero-engines. The review includes independent and inte- grated finishing and strengthening technologies and dis- cusses advanced rotational abrasive flow machining with back-pressure used for finishing the integral impeller and blisk. A brief assessment of future research problems and directions is also presented.

Experimental Study on Dynamic Mechanical Properties of Sprayed Concrete-Surrounding Rock Combined Body

To investigate the dynamic response problem of the double medium formed by the adherence of sprayed concrete and surrounding rock in the tunnel,a split Hopkinson pressure bar of 75 mm in diameter was adopted at the ages of 3,7 and 10 d.Experimental results showed that dynamic compressive strength and dynamic increase factors(DIF)of the combined bodies increase with the strain rate.With the growth of strain rate,the critical strain of the combined bodies first increases,then deceases.Furthermore,the combined bodies of 3 d reveal the plastic property and brittle property for 7 d and 10 d when the strain rate is over 80/s.The failure characteristic of the sprayed concrete changes from tearing strain damage to crushing damage as the growth of strain rate,and the failure characteristic of rock presents the tensile failure mode as demonstrated by the scanning electron microscope(SEM).

Wideband mid-infrared thermal emitter based on stacked nanocavity metasurfaces

Efficient thermal radiation in the mid-infrared(M-IR)region is of supreme importance for many applications including thermal imaging and sensing,thermal infrared light sources,infrared spectroscopy,emissivity coatings,and camouflage.The ability to control light makes metasurfaces an attractive platform for infrared applications.Recently,different metamaterials have been proposed to achieve high thermal radiation.To date,broadening the radiation bandwidth of a metasurface emitter(meta-emitter)has become a key goal to enable extensive applications.We experimentally demonstrate a broadband M-IR thermal emitter using stacked nanocavity metasurface consisting of two pairs of circular-shaped dielectric(Si;N;)–metal(Au)stacks.A high thermal radiation can be obtained by engineering the geometry of nanocavity metasurfaces.Such a meta-emitter provides wideband and broad angular absorptance of both p-and s-polarized light,offering a wideband thermal radiation with an average emissivity of more than 80%in the M-IR atmospheric window of 8–14μm.The experimental illustration together with the theoretical framework establishes a basis for designing broadband thermal emitters,which,as anticipated,will initiate a promising avenue to M-IR sources.

Towards atomic and close-to-atomic scale manufacturing

Human beings have witnessed unprecedented developments since the 1760s using precision tools and manufacturing methods that have led to ever-increasing precision,from millimeter to micrometer,to single nanometer,and to atomic levels.The modes of manufacturing have also advanced from craft-based manufacturing in the Stone,Bronze,and Iron Ages to precisioncontrollable manufacturing using automatic machinery.In the past 30 years,since the invention of the scanning tunneling microscope,humans have become capable of manipulating single atoms,laying the groundwork for the coming era of atomic and close-to-atomic scale manufacturing(ACSM).Close-to-atomic scale manufacturing includes all necessary steps to convert raw materials,components,or parts into products designed to meet the user’s specifications.The processes involved in ACSM are not only atomically precise but also remove,add,or transform work material at the atomic and close-to-atomic scales.This review discusses the history of the development of ACSM and the current state-of-the-art processes to achieve atomically precise and/or atomic-scale manufacturing.Existing and future applications of ACSM in quantum computing,molecular circuitry,and the life and material sciences are also described.To further develop ACSM,it is critical to understand the underlying mechanisms of atomic-scale and atomically precise manufacturing;develop functional devices,materials,and processes for ACSM;and promote high throughput manufacturing.

Multi-cycle reconfigurable THz extraordinary optical transmission using chalcogenide metamaterials

Metamaterials composed of metallic antennae arrays are used as they possess extraordinary optical transmission(EOT)in the terahertz(THz)region,whereby a giant forward light propagation can be created using constructive interference of tunneling surface plasmonic waves.However,numerous applications of THz meta-devices demand an active manipula-tion of the THz beam in free space.Although some studies have been carried out to control the EOT for the THz region,few of these are based upon electrical modulation of the EOT phenomenon,and novel strategies are required for act-ively and dynamically reconfigurable EOT meta-devices.In this work,we experimentally present that the EOT resonance can be coupled to optically reconfigurable chalcogenide metamaterials which offers a reversible all-optical control of the THz light.A modulation efficiency of 88%in transmission at 0.85 THz is experimentally observed using the EOT metama-terials,which is composed of a gold(Au)circular aperture array sitting on a non-volatile chalcogenide phase change ma-terial(Ge2Sb2Te5)film.This comes up with a robust and ultrafast reconfigurable EOT over 20 times of switching,excited by a nanosecond pulsed laser.The measured data have a good agreement with finite-element-method numerical simula-tion.This work promises THz modulators with significant on/off ratios and fast speeds.

Overview of extreme manufacturing

1.Introduction Today we live in a new era of economic globalization and rapid technological growth.The advancement of both our society and standard of living require us to delve into this new world and unleash the possibilities our future.We need to broaden the horizons of our universe to discover a new realm where the future of humanity can flourish.We need to be unafraid to unveil the mysteries hidden within the depths of our oceans to unearth treasures that will benefit not only us,but the generations to come.To fulfill this vision,we must manufacture extremely large and extraordinarily fast equipment that will function seamlessly under the duress of extreme environments.On the other hand,matter is infinitely divisible.

Compound-mode crack propagation law of PMMA semicirculararch roadway specimens under impact loading

An underground roadway usually contains defects of various types,and when the roadway is subjected to external loading,the locations of those defects influence the roadway by differing degrees.In this study,to study how the locations of defects affect crack propagation in a roadway,specimens with tunnel-type voids were made using polymethyl methacrylate,and the stress wave produced by a bullet impacting an incident rod was used as the impact load.Meanwhile,the variations in crack speed,displacement,and dynamic stress intensity factor during crack propagation were obtained using an experimental system of digital laser dynamic caustics,and the commercial software ABAQUS was used for numerical simulations.From the experiments and numerical simulations,the crack propagation path was verified and the impact fracture behavior of a semicircular-arch roadway with different defect positions was presented.The results show that when the pre-fabricated crack is on the central axis of the sample,the crack propagation is purely mode I;when the pre-fabricated crack is 5 mm from the central axis,the crack propagation alternates between mode I and a mixture of modes I and II;when the pre-fabricated crack is at the edge of the semicircular-arch roadway,the crack propagation follows the I-II mixed mode.

Investigation of the trajectory uniformity in water dissolution ultraprecision continuous polishing of large-sized KDP crystal

Large-sized potassium dihydrogen phosphate(KDP)crystals are an irreplaceable nonlinear optical component in an inertial confinement fusion project.Restricted by the size,previous studies have been aimed mainly at the removal principle and surface roughness of small-sized KDP crystals,with less research on flatness.Due to its low surface damage and high machining efficiency,water dissolution ultraprecision continuous polishing(WDUCP)has become a good technique for processing large-sized KDP crystals.In this technique,the trajectory uniformity of water droplets can directly affect the surface quality,such as flatness and roughness.Specifically,uneven trajectory distribution of water droplets on the surface of KDP crystals derived from the mode of motion obviously affects the surface quality.In this study,the material removal mechanism of WDUCP was introduced.A simulation of the trajectory of water droplets on KDP crystals under different eccentricity modes of motion was then performed.Meanwhile,the coefficient of variation(CV)was utilized to evaluate the trajectory uniformity.Furthermore,to verify the reliability of the simulation,some experimental tests were also conducted by employing a large continuous polisher.The results showed that the CV varied from 0.67 to 2.02 under the certain eccentricity mode of motion and varied from 0.48 to 0.65 under the uncertain eccentricity mode of motion.The CV of uncertain eccentricity is always smaller than that of certain eccentricity.Hence,the uniformity of trajectory was better under uncertain eccentricity.Under the mode of motion of uncertain eccentricity,the initial surface texture of the100 mm×100 mm×10 mm KDP crystal did achieve uniform planarization.The surface root mean square roughness was reduced to 2.182 nm,and the flatness was reduced to 22.013μm.Therefore,the feasibility and validity of WDUCP for large-sized KDP crystal were verified.

Foreword for the inaugural issue

The International Journal of Extreme Manufacturing is a leading,worldwide scientific journal focused on the fields of extreme manufacturing.Published within it are the latest scientific and engineering achievements in related fields,as well as pioneering scientific,technological,and engineering innovations and developments.

Research progress on ultra-precision machining technologies for soft-brittle crystal materials

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 diff^culties 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.

Hole quality in longitudinal–torsional coupled ultrasonic vibration assisted drilling of carbon fiber reinforced plastics

Carbon fiber reinforced plastic (CFRP) composites are extremely attractive in the manufacturing of structural and functional components in the aircraft manufacturing field due to their outstanding properties, such as good fatigue resistance, high specific stiffness/strength, and good shock absorption. However, because of their inherent anisotropy, low interlamination strength, and abrasive characteristics, CFRP composites are considered difficult-to-cut materials and are prone to generating serious hole defects, such as delamination, tearing, and burrs. The advanced longitudinal–torsional coupled ultrasonic vibration assisted drilling (LTC-UAD) method has a potential application for drilling CFRP composites. At present, LTC-UAD is mainly adopted for drilling metal materials and rarely for CFRP. Therefore, this study analyzes the kinematic characteristics and the influence of feed rate on the drilling performance of LTC-UAD. Experimental results indicate that LTC-UAD can reduce the thrust force by 39% compared to conventional drilling. Furthermore, LTC-UAD can decrease the delamination and burr factors and improve the surface quality of the hole wall. Thus, LTC-UAD is an applicable process method for drilling components made with CFRP composites.

Advances in molecular dynamics simulation of ultra-precision machining of hard and brittle materials

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.

Atomistic understanding of interfacial processing mechanism of silicon in water environment:A ReaxFF molecular dynamics simulation

The interfacial wear between silicon and amorphous silica in water environment is critical in numerous applications.However,the understanding regarding the micro dynamic process is still unclear due to the limitations of apparatus.Herein,reactive force field simulations are utilized to study the interfacial process between silicon and amorphous silica in water environment,exploring the removal and damage mechanism caused by pressure,velocity,and humidity.Moreover,the reasons for high removal rate under high pressure and high velocity are elucidated from an atomic perspective.Simulation results show that the substrate is highly passivated under high humidity,and the passivation layer could alleviate the contact between the abrasive and the substrate,thus reducing the damage and wear.In addition to more Si-O-Si bridge bonds formed between the abrasive and the substrate,new removal pathways such as multibridge bonds and chain removal appear under high pressure,which cause higher removal rate and severer damage.At a higher velocity,the abrasive can induce extended tribochemical reactions and form more interfacial Si-O-Si bridge bonds,hence increasing removal rate.These results reveal the internal cause of the discrepancy in damage and removal rate under different conditions from an atomic level.

Experimental study on high-efficiency polishing for potassium dihydrogen phosphate (KDP) crystal by using two-phase air-water fluid

A high-efficiency polishing approach using two-phase air–water fluid(TAWF)is proposed to avoid surface contamination and solve the inefficiency of previous water-dissolution polishing techniques for potassium dihydrogen phosphate(KDP)crystal.In the proposed method,controllable deliquescence is implemented without any chemical impurity.The product of deliquescence is then removed by a polishing pad to achieve surface planarization.The mechanism underlying TAWF polishing is analyzed,a special device is built to polish the KDP crystal,and the effect of relative humidity(RH)on polishing performance is studied.The relationship between key parameters of polishing and surface planarization is also investigated.Results show that the polishing performance is improved with increasing RH.However,precisely controlling the RH is extremely difficult during TAWF polishing.Controllable deliquescence can easily be disrupted once the RH fluctuates,which therefore needs to be restricted to a low level to avoid its influence on deliquescence rate.The material removal of TAWF polishing is mainly attributed to the synergistic effect of deliquescence and the polishing pad.Excessive polishing pressure and revolution rate remarkably reduce the life of the polishing pad and the surface quality of the KDP crystal.TAWF polishing using IC-1000 and TEC-168S increase the machining efficiency by 150%,and a smooth surface with a root mean square surface roughness of 5.5 nm is obtained.

Smoothed-Particle Hydrodynamics Investigation on Brittle-Ductile Transition of Quartz Glass in Single-Grain Grinding Process

The smoothed-particle hydrodynamics(SPH)method was introduced to simulate the quartz glass grinding process with a single grain under micrp-nano scale.To investigate the mechanism of brittle-ductile transition,such factors as the machin-ing depth,grinding force,maximum equivalent stress,and residual stress were analyzed.The simulation results indicate that quartz glass can be machined in a ductile mode under a certain condition.In this paper,the occurrence and propaga-tion of cracks in quartz glass at different grinding depths(0.1-1μm)are observed,and the critical depth of brittle-ductile transformation is 0.36 pum.At different grinding depths,the grinding force ratio is greater than 1.When the cutting depth is 0.4 um,the crack propagation depth is about 1.2μm,which provides a basis for the prediction of subsurface damage depth.In addition,the correctness of the simulation result was verified by carrying out scratch experiments of varying cutting depth on optical quartz glass.

Comparison of surface integrity for dry and wet drilling of 49Fe-49Co-2V alloy

Working performances of the components made out of 49Fe-49Co-2V alloy are closely related to the surface integrity of the drilled holes,which are influenced remarkably by the cooling conditions.The present study focuses on the surface integrity differences between wet and dry drilled 49Fe-49Co-2V alloy holes.The drilled hole surface roughness and topographies,metallurgical and mechanical properties,and the exit characterizations were obtained using optical microscopy(OM),scanning electron microscopy(SEM),electron backscatter diffraction microscopy(EBSD),transmission electron microscopy(TEM),energy dispersive spectroscopy(EDS)and Vickers hardness techniques,etc.The effects of cooling conditions on the surface integrity were concluded and the influence mechanisms were analyzed based on the force and temperature differences in drilling process with different cooling conditions.It is found that the surface roughness and the thickness of refined-grain region of the dry drilled holes are larger than those of wet drilled holes;work hardening induced by wet drilling is more serious than dry drilling;chippings occurred in the exits of the wet drilled holes due to the material brittleness,which could be avoided by dry drilling.The surface integrity differences of wet and dry drilled holes are closely related to the force and temperature differences in drilling process with different cooling conditions.

Special issue： Ultra-precision machining

This special issue in Frontiers of Mechanical Engineering contains seventeen papers contributed by prestigious experts from five countries, including one prospect paper, four research papers and twelve review papers. These papers cover a broad area of the ultra-precision machining, and focus on the recent advances on a wide variety of machining methods, such as precision molding, figuring, milling, lapping and diamond machining, to illustrate how various materials in the macro-scale or micro-scale can be machined with high precision, low surface^subsurface damage and ultra-smooth surfaces to meet the demands of numerous application areas, including high-power laser systems, consumer electronics, flexible devices, etc. Some other hot topics, such as the measurement and simulation technology in the ultra-precision machining field, are also covered to provide the readers with a more comprehensive view.

Special issue： Near-net shaping technology

Near-net shaping is an efficient, economical and environmentally-friendly approach to manufacture products which are very close to the final shape, reducing the need for surface finishing. It has become more and more important to use raw materials and energy in an optimal way. Near-net shaping technology has attracted increasing attention in both academic and industrial communities, especially in China, because China has become the world＇s largest regional market for main material forming methods, such as casting, forging and injection molding. The main objective of this special issue in Frontiers of Mechanical Engineering is to bring together the leading ideas, experience and research results of academic scientists and researchers on various aspects of near-net shaping technology. This special issue contains eleven papers contributed by prestigious experts from different countries, including four reviews and seven research articles. These papers cover a broad area of the near-net shaping technology,