NANOSCALE CUTTING OF MONOCRYSTALLINE SILICON USING MOLECULAR DYNAMICS SIMULATION

It has been found that the brittle material, monocrystalline silicon, can be machined in ductile mode in nanoscale cutting when the tool cutting edge radius is reduced to nanoscale and the undeformed chip thickness is smaller than the tool edge radius. In order to better understand the mechanism of ductile mode cutting of silicon, the molecular dynamics （MD） method is employed to simulate the nanoscale cutting of monocrystalline silicon. The simulated variation of the cutting forces with the tool cutting edge radius is compared with the cutting force results from experimental cutting tests and they show a good agreement. The results also indicate that there is silicon phase transformation from monocrystalline to amorphous in the chip formation zone that can be used to explain the cause of ductile mode cutting. Moreover, from the simulated stress results, the two necessary conditions of ductile mode cutting, the tool cutting edge radius are reduced to nanoscale and the undeformed chip thickness should be smaller than the tool cutting edge radius, have been explained.

Investigation of a dynamics-oriented engineering approach to ultraprecision machining of freeform surfaces and its implementation perspectives

In current precision and ultraprecision machining practice,the positioning and control of actuation systems,such as slideways and spindles,are heavily dependent on the use of linear or rotary encoders.However,positioning control is passive because of the lack of direct monitoring and control of the tool and workpiece positions in the dynamic machining process and also because it is assumed that the machining system is rigid and the cutting dynamics are stable.In ultraprecision machining of freeform surfaces using slow tool servo mode in particular,however,account must be taken of the machining dynamics and dynamic synchronization of the cutting tool and workpiece positioning.The important question also arises as to how ultraprecision machining systems can be designed and developed to work better in this application scenario.In this paper,an innovative dynamics-oriented engineering approach is presented for ultraprecision machining of freeform surfaces using slow tool servo mode.The approach is focused on seamless integration of multibody dynamics,cutting forces,and machining dynamics,while targeting the positioning and control of the tool–workpiece loop in the machining system.The positioning and motion control between the cutting tool and workpiece surface are further studied in the presence of interfacial interactions at the tool tip and workpiece surface.The interfacial cutting physics and dynamics are likely to be at the core of in-process monitoring applicable to ultraprecision machining systems.The approach is illustrated using a virtual machining system developed and supported with simulations and experimental trials.Furthermore,the paper provides further explorations and discussion on implementation perspectives of the approach,in combination with case studies,as well as discussing its fundamental and industrial implications.

Modeling the effects of mechanical parameters on the hydrodynamic behavior of vertical current classifiers

This study modeled the effects of structural and dimensional manipulations on hydrodynamic behavior of a bench vertical current classifier. Computational fluid dynamics （CFD） approach was used as modeling method, and turbulent intensity and fluid velocity were applied as system responses to predict the over- flow cut size variations. These investigations showed that cut size would decrease by increasing diameter and height of the separation column and cone section depth, due to the decrease of turbulent intensity and fluid velocity. As the size of discharge gate increases, the overflow cut-size would decrease due to freely fluid stream out of the column. The overflow cut-size was significantly increased in downward fed classifier compared to that fed by upward fluid stream. In addition, reforming the shape of angular overflow outlet＇s weir into the curved form prevented stream inside returning and consequently unselec- tire cut-size decreasing.

From the new Austrian tunneling method to the geoengineering condition evaluation and dynamic controlling method

The new Austrian tunneling method （NATM） is widely applied in design and construction of underground engineering projects. When the type and distribution of unfavorable geological bodies （UGBs） associated with their influences on geoengineering are complicated or unfortunately are overlooked, we should pay more attentions to internal features of rocks grades IV and V （even in local but mostly controlling zones）. With increasing attentions to the characteristics, mechanism and influences of engineering construction-triggered geohazards, it is crucial to fully understand the disturbance of these geohazards on project construction. A reasonable determination method in construction procedure, i.e. the shape of working face, the type of engineering support and the choice of feasible procedure, should be considered in order to mitigate the construction-triggered geohazards. Due to their high sensitivity to groundwater and in-situ stress, various UGBs exhibit hysteretic nature and failure modes. To give a complete understanding on the internal causes, the emphasis on advanced comprehensive geological forecasting and overall reinforcement treatment is therefore of more practical significance. Compre- hensive evaluation of influential factors, identification of UGB, and measures of discontinuity dynamic controlling comprises the geoengineering condition evaluation and dynamic controlling method. In a case of a cut slope, the variations of UGBs and the impacts of key environmental factors are presented, where more severe construction-triggered geohazards emerged in construction stage than those predicted in design and field investigation stages. As a result, the weight ratios of different influential factors with respect to field investigation, design and construction are obtained.

Solution and Analysis of Chatter Stability for End Milling in the Time-domain

In this paper, the instantaneous undeformed chip thickness is modeled to include the dynamic modulation caused by the tool vibration while the dynamic regenerative effects are taken into account. The numerical method is used to solve the differential equations goveming the dynamics of the milling system. Several chatter detection criteria are applied synthetically to the simulated signals and the stability diagram is obtained in time-domain. The simulation results in time-domain show a good agreement with the analytical prediction, which is validated by the cutting experiments. By simulating the chatter stability lobes in the time-domain and analyzing the influences of different spindle speeds on the vibration amplitudes of the tool under a Fixed chip-load condition, conclusions could be drawn as follows： In rough milling, higher machining efficiency can be achieved by selecting a spindle speed corresponding to the axial depth of cut in accordance with the simulated chatter stability lobes, and in Fmish milling, lower surface roughness can be achieved by selecting a spindle speed well beyond the resonant frequency of machining system.