On dry machining of AZ31B magnesium alloy using textured cutting tool inserts

Magnesium alloys have many advantages as lightweight materials for engineering applications,especially in the fields of automotive and aerospace.They undergo extensive cutting or machining while making products out of them.Dry cutting,a sustainable machining method,causes more friction and adhesion at the tool-chip interface.One of the promising solutions to this problem is cutting tool surface texturing,which can reduce tool wear and friction in dry cutting and improve machining performance.This paper aims to investigate the impact of dimple textures(made on the flank face of cutting inserts)on tool wear and chip morphology in the dry machining of AZ31B magnesium alloy.The results show that the cutting speed was the most significant factor affecting tool flank wear,followed by feed rate and cutting depth.The tool wear mechanism was examined using scanning electron microscope(SEM)images and energy dispersive X-ray spectroscopy(EDS)analysis reports,which showed that at low cutting speed,the main wear mechanism was abrasion,while at high speed,it was adhesion.The chips are discontinuous at low cutting speeds,while continuous at high cutting speeds.The dimple textured flank face cutting tools facilitate the dry machining of AZ31B magnesium alloy and contribute to ecological benefits.

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community:a comparative analysis

The aerospace community widely uses difficult-to-cut materials,such as titanium alloys,high-temperature alloys,metal/ceramic/polymer matrix composites,hard and brittle materials,and geometrically complex components,such as thin-walled structures,microchannels,and complex surfaces.Mechanical machining is the main material removal process for the vast majority of aerospace components.However,many problems exist,including severe and rapid tool wear,low machining efficiency,and poor surface integrity.Nontraditional energy-assisted mechanical machining is a hybrid process that uses nontraditional energies(vibration,laser,electricity,etc)to improve the machinability of local materials and decrease the burden of mechanical machining.This provides a feasible and promising method to improve the material removal rate and surface quality,reduce process forces,and prolong tool life.However,systematic reviews of this technology are lacking with respect to the current research status and development direction.This paper reviews the recent progress in the nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in the aerospace community.In addition,this paper focuses on the processing principles,material responses under nontraditional energy,resultant forces and temperatures,material removal mechanisms,and applications of these processes,including vibration-,laser-,electric-,magnetic-,chemical-,advanced coolant-,and hybrid nontraditional energy-assisted mechanical machining.Finally,a comprehensive summary of the principles,advantages,and limitations of each hybrid process is provided,and future perspectives on forward design,device development,and sustainability of nontraditional energy-assisted mechanical machining processes are discussed.

Field-assisted machining of difficult-to-machine materials

Difficult-to-machine materials (DMMs) are extensively applied in critical fields such as aviation,semiconductor,biomedicine,and other key fields due to their excellent material properties.However,traditional machining technologies often struggle to achieve ultra-precision with DMMs resulting from poor surface quality and low processing efficiency.In recent years,field-assisted machining (FAM) technology has emerged as a new generation of machining technology based on innovative principles such as laser heating,tool vibration,magnetic magnetization,and plasma modification,providing a new solution for improving the machinability of DMMs.This technology not only addresses these limitations of traditional machining methods,but also has become a hot topic of research in the domain of ultra-precision machining of DMMs.Many new methods and principles have been introduced and investigated one after another,yet few studies have presented a comprehensive analysis and summarization.To fill this gap and understand the development trend of FAM,this study provides an important overview of FAM,covering different assisted machining methods,application effects,mechanism analysis,and equipment design.The current deficiencies and future challenges of FAM are summarized to lay the foundation for the further development of multi-field hybrid assisted and intelligent FAM technologies.

Stress-assisted corrosion mechanism of 3Ni steel by using gradient boosting decision tree machining learning method

Traditional 3Ni weathering steel cannot completely meet the requirements for offshore engineering development,resulting in the design of novel 3Ni steel with the addition of microalloy elements such as Mn or Nb for strength enhancement becoming a trend.The stress-assisted corrosion behavior of a novel designed high-strength 3Ni steel was investigated in the current study using the corrosion big data method.The information on the corrosion process was recorded using the galvanic corrosion current monitoring method.The gradi-ent boosting decision tree(GBDT)machine learning method was used to mine the corrosion mechanism,and the importance of the struc-ture factor was investigated.Field exposure tests were conducted to verify the calculated results using the GBDT method.Results indic-ated that the GBDT method can be effectively used to study the influence of structural factors on the corrosion process of 3Ni steel.Dif-ferent mechanisms for the addition of Mn and Cu to the stress-assisted corrosion of 3Ni steel suggested that Mn and Cu have no obvious effect on the corrosion rate of non-stressed 3Ni steel during the early stage of corrosion.When the corrosion reached a stable state,the in-crease in Mn element content increased the corrosion rate of 3Ni steel,while Cu reduced this rate.In the presence of stress,the increase in Mn element content and Cu addition can inhibit the corrosion process.The corrosion law of outdoor-exposed 3Ni steel is consistent with the law based on corrosion big data technology,verifying the reliability of the big data evaluation method and data prediction model selection.

Effect of tool geometry on ultraprecision machining of soft-brittle materials:a comprehensive review

Brittle materials are widely used for producing important components in the industry of optics,optoelectronics,and semiconductors.Ultraprecision machining of brittle materials with high surface quality and surface integrity helps improve the functional performance and lifespan of the components.According to their hardness,brittle materials can be roughly divided into hard-brittle and soft-brittle.Although there have been some literature reviews for ultraprecision machining of hard-brittle materials,up to date,very few review papers are available that focus on the processing of soft-brittle materials.Due to the‘soft’and‘brittle’properties,this group of materials has unique machining characteristics.This paper presents a comprehensive overview of recent advances in ultraprecision machining of soft-brittle materials.Critical aspects of machining mechanisms,such as chip formation,surface topography,and subsurface damage for different machining methods,including diamond turning,micro end milling,ultraprecision grinding,and micro/nano burnishing,are compared in terms of tool-workpiece interaction.The effects of tool geometries on the machining characteristics of soft-brittle materials are systematically analyzed,and dominating factors are sorted out.Problems and challenges in the engineering applications are identified,and solutions/guidelines for future R&D are provided.

Laser machining fundamentals:micro,nano,atomic and close-to-atomic scales

With the rapid development in advanced industries,such as microelectronics and optics sectors,the functional feature size of devises/components has been decreasing from micro to nanometric,and even ACS for higher performance,smaller volume and lower energy consumption.By this time,a great many quantum structures are proposed,with not only an extreme scale of several or even single atom,but also a nearly ideal lattice structure with no material defect.It is almost no doubt that such structures play critical role in the next generation products,which shows an urgent demand for the ACSM.Laser machining is one of the most important approaches widely used in engineering and scientific research.It is high-efficient and applicable for most kinds of materials.Moreover,the processing scale covers a huge range from millimeters to nanometers,and has already touched the atomic level.Laser–material interaction mechanism,as the foundation of laser machining,determines the machining accuracy and surface quality.It becomes much more sophisticated and dominant with a decrease in processing scale,which is systematically reviewed in this article.In general,the mechanisms of laser-induced material removal are classified into ablation,CE and atomic desorption,with a decrease in the scale from above microns to angstroms.The effects of processing parameters on both fundamental material response and machined surface quality are discussed,as well as theoretical methods to simulate and understand the underlying mechanisms.Examples at nanometric to atomic scale are provided,which demonstrate the capability of laser machining in achieving the ultimate precision and becoming a promising approach to ACSM.

Failure mode change and material damage with varied machining speeds:a review

High-speed machining(HSM) has been studied for several decades and has potential application in various industries, including the automobile and aerospace industries. However,the underlying mechanisms of HSM have not been formally reviewed thus far. This article focuses on the solid mechanics framework of adiabatic shear band(ASB) onset and material metallurgical microstructural evolutions in HSM. The ASB onset is described using partial differential systems. Several factors in HSM were considered in the systems, and the ASB onset conditions were obtained by solving these systems or applying the perturbation method to the systems. With increasing machining speed, an ASB can be depressed and further eliminated by shock pressure. The damage observed in HSM exhibits common features. Equiaxed fine grains produced by dynamic recrystallization widely cause damage to ductile materials, and amorphization is the common microstructural evolution in brittle materials. Based on previous studies, potential mechanisms for the phenomena in HSM are proposed. These include the thickness variation of the white layer of ductile materials. These proposed mechanisms would be beneficial to deeply understanding the various phenomena in HSM.

A New Dynamics Analysis Model for Five-Axis Machining of Curved Surface Based on Dimension Reduction and Mapping

The equipment used in various fields contains an increasing number of parts with curved surfaces of increasing size.Five-axis computer numerical control(CNC)milling is the main parts machining method,while dynamics analysis has always been a research hotspot.The cutting conditions determined by the cutter axis,tool path,and workpiece geometry are complex and changeable,which has made dynamics research a major challenge.For this reason,this paper introduces the innovative idea of applying dimension reduction and mapping to the five-axis machining of curved surfaces,and proposes an efficient dynamics analysis model.To simplify the research object,the cutter position points along the tool path were discretized into inclined plane five-axis machining.The cutter dip angle and feed deflection angle were used to define the spatial position relationship in five-axis machining.These were then taken as the new base variables to construct an abstract two-dimensional space and establish the mapping relationship between the cutter position point and space point sets to further simplify the dimensions of the research object.Based on the in-cut cutting edge solved by the space limitation method,the dynamics of the inclined plane five-axis machining unit were studied,and the results were uniformly stored in the abstract space to produce a database.Finally,the prediction of the milling force and vibration state along the tool path became a data extraction process that significantly improved efficiency.Two experiments were also conducted which proved the accuracy and efficiency of the proposed dynamics analysis model.This study has great potential for the online synchronization of intelligent machining of large surfaces.

Assessment of Lubrication Property and Machining Performance of Nanofluid Composite Electrostatic Spraying(NCES)Using Different Types of Vegetable Oils as Base Fluids of External Fluid

The current study of minimum quantity lubrication(MQL)concentrates on its performance improvement.By contrast with nanofluid MQL and electrostatic atomization(EA),the proposed nanofluid composite electrostatic spraying(NCES)can enhance the performance of MQL more comprehensively.However,it is largely influenced by the base fluid of external fluid.In this paper,the lubrication property and machining performance of NCES with different types of vegetable oils(castor,palm,soybean,rapeseed,and LB2000 oil)as the base fluids of external fluid were compared and evaluated by friction and milling tests under different flow ratios of external and internal fluids.The spraying current and electrowetting angle were tested to analyze the influence of vegetable oil type as the base fluid of external fluid on NCES performances.The friction test results show that relative to NCES with other vegetable oils as the base fluids of external fluid,NCES with LB2000 as the base fluid of external fluid reduced the friction coefficient and wear loss by 9.4%-27.7%and 7.6%-26.5%,respectively.The milling test results display that the milling force and milling temperature for NCES with LB2000 as the base fluid of external fluid were 1.4%-13.2%and 3.6%-11.2%lower than those for NCES with other vegetable oils as the base fluids of external fluid,respectively.When LB2000/multi-walled carbon nanotube(MWCNT)water-based nanofluid was used as the external/internal fluid and the flow ratio of external and internal fluids was 2:1,NCES showed the best milling performance.This study provides theoretical and technical support for the selection of the base fluid of NCES external fluid.

Powder mixed electrochemical discharge process for micro machining of C103 niobium alloy

This work demonstrates the viability of the powder-mixed micro-electrochemical discharge machining(PMECDM) process to fabricate micro-holes on C103 niobium-based alloy for high temperature applications.Three processes are involved simultaneously i.e.spark erosion,chemical etching,and abrasive grinding for removal of material while the classical electrochemical discharge machining process involves double actions i.e.spark erosion,and chemical etching.The powder-mixed electrolyte process resulted in rapid material removal along with a better surface finish as compared to the classical microelectrochemical discharge machining(MECDM).Further,the results are optimized through a multiobjective optimization approach and study of the surface topography of the hole wall surface obtained at optimized parameters.In the selected range of experimental parameters,PMECDM shows a higher material removal rate(MRR) and lower surface roughness(R_(a))(MRR:2.8 mg/min and R_(a) of 0.61 μm) as compared to the MECDM process(MRR:2.01 mg/min and corresponding Raof 1.11 μm).A detailed analysis of the results is presented in this paper.

Optimization of CNC Turning Machining Parameters Based on Bp-DWMOPSO Algorithm

Cutting parameters have a significant impact on the machining effect.In order to reduce the machining time and improve the machining quality,this paper proposes an optimization algorithm based on Bp neural networkImproved Multi-Objective Particle Swarm(Bp-DWMOPSO).Firstly,this paper analyzes the existing problems in the traditional multi-objective particle swarm algorithm.Secondly,the Bp neural network model and the dynamic weight multi-objective particle swarm algorithm model are established.Finally,the Bp-DWMOPSO algorithm is designed based on the established models.In order to verify the effectiveness of the algorithm,this paper obtains the required data through equal probability orthogonal experiments on a typical Computer Numerical Control(CNC)turning machining case and uses the Bp-DWMOPSO algorithm for optimization.The experimental results show that the Cutting speed is 69.4 mm/min,the Feed speed is 0.05 mm/r,and the Depth of cut is 0.5 mm.The results show that the Bp-DWMOPSO algorithm can find the cutting parameters with a higher material removal rate and lower spindle load while ensuring the machining quality.This method provides a new idea for the optimization of turning machining parameters.

Prediction of Wearing of Cutting Tools Using Real Time Machining Parameters and Temperature Using Rayleigh-Ham Method

Wear of cutting tools is a big concern for industrial manufacturers, because of their acquisition cost as well as the impact on the production lines when they are unavailable. Law of wear is very important in determining cutting tools lifespan, but most of the existing models don’t take into account the cutting temperature. In this work, the theoretical and experimental results of a dynamic study of metal machining against cutting temperature of a treated steel of grade S235JR with a high-speed steel tool are provided. This study is based on the analysis of two complementary approaches, an experimental approach with the measurement of the temperature and on the other hand, an approach using modeling. Based on unifactorial and multifactorial tests (speed of cut, feed, and depth of cut), this study allowed the highlighting of the influence of the cutting temperature on the machining time. To achieve this objective, two specific approaches have been selected. The first was to measure the temperature of the cutting tool and the second was to determine the wear law using Rayleigh-Ham dimensional analysis method. This study permitted the determination of a law that integrates the cutting temperature in the calculations of the lifespan of the tools during machining.

Experimental Study on Entropy Features in Machining Vibrations of A Thin-Walled Tubular Workpiece

In machining processes,chatter vibrations are always regarded as one of the major limitations for production quality and efficiency.Accurate and timely monitoring of chatter is helpful to maintain stable machining operations.At present,most chatter monitoring methods are based on the energy level at specified chatter frequencies or frequency bands.However,the spectral features of chatter could change during machining operations due to complexity and time-varying dynamics of the physical machining process.The purpose of this paper is to investigate the time-varying chatter features in turning of thin-walled tubular workpieces from the perspective of entropy.The airborne acoustics was selected as the source of information for machining condition monitoring.First,corresponding to the distinguishing surface topographies relevant to machining conditions,the features of the sound signal emitted during turning of the thin-walled cylindrical workpieces were extracted using the spectral analysis and wavelet packet transform,respectively.It was shown that the dominant vibration frequency as well as the energy distribution could shift with the transition of the machining status.After that,two relative entropy indicators based on the spectrum and the wavelet packet energy were constructed to identify chattering events in turning of the thin-walled tubes.The experimental results demonstrate that the proposed indicators could accurately reflect the transition of machining conditions with high sensitivity and robustness in comparison with the traditional FFT-based methods.The achievement of this study lays the foundations of the online chatter monitoring and control technique for turning of the thin-walled tubular workpieces.

Structure Improvement and Optimization of Gantry Milling System for Complex Boring and Milling Machining Center

To enhance the efficiency and machining precision of the TX1600G complex boring and milling machining center,a study was conducted on the structure of its gantry milling system.This study aimed to mitigate the influence of factors such as structural quality,natural frequency,and stiffness.The approach employed for this investigation involved mechanism topology optimization.To initiate this process,a finite element model of the gantry milling system structure was established.Subsequently,an objective function,comprising strain energy and modal eigenvalues,was synthesized.This objective function was optimized through multi-objective topology optimization,taking into account certain mass fraction constraints and considering various factors,including processing technology.The ultimate goal of this optimization was to create a gantry milling structure that exhibited high levels of dynamic and static stiffness,a superior natural frequency,and reduced mass.To validate the effectiveness of these topology optimization results,a comparison was made between the new and previous structures.The findings of this study serve as a valuable reference for optimizing the structure of other components within the machining center.

Monitoring Computer Numerical Control Machining Progress Based on Information Fusion

To cope with the market demand dynamically,enterprise needs to obtain the production status of work in process real-timely,but the information of machining progress has feature of uncertainty and can not reflect the status of production field effectively.In this work,to overcome the ineffectiveness of computer numerical control(CNC) machining progress information extraction and its application restriction in practice because of heterogeneous system of CNC machine,based on information fusion by analyzing multi-sources information,estimating CNC machining status and predicting the machining progress through tracking tool coordinates,a CNC machining progress monitoring method is presented.The multi-sources heterogeneous information includes machining path,real-time spindle power information,manual input data and tool position.On the method of obtaining this multi-sources heterogeneous information,the method which helps explore numerical control(NC) program,monitor spindle power of CNC,collect human-computer interaction(HCI) information,obtain real-time tool coordinates and express the knowledge concerned in this field is analyzed; The decision rule of CNC machining status in the way of fusing multi-sources information in manufacturing process is summarized,as well as the machining progress tracking method in accordance with real-time tool coordinates and machining path is presented.Finally,the method discussed is proved feasible by the verification of machining progress tracking through simulation experiment.The proposed research realizes the effective integration of CNC machining progress information,and enables enterprises an efficient way to share CNC information and configure CNC resources optimally.

Machining Line Planner输出STEP-NC数控程序的研究

介绍了STEP-NC的概念、数据模型及其结构特点,然后通过对比MLP(Machining Line Planner)和STEP-NC数控程序对特征和操作的不同定义方法,分析了在MLP中特征及加工工艺与STEP-NC的对应关系,探讨了在MLP中实现输出STEP-NC格式的零件加工程序的方法。

Smart Cutting Tools and Smart Machining: Development Approaches, and Their Implementation and Application Perspectives

Smart machining has tremendous potential and is becoming one of new generation high value precision manufacturing technologies in line with the advance of Industry 4.0 concepts. This paper presents some innovative design concepts and, in particular, the development of four types of smart cutting tools, including a force-based smart cutting tool, a temperature-based internally-cooled cutting tool, a fast tool servo （FTS） and smart collets for ultra- precision and micro manufacturing purposes. Implemen- tation and application perspectives of these smart cutting tools are explored and discussed particularly for smart machining against a number of industrial application requirements. They are contamination-free machining, machining of tool-wear-prone Si-based infra-red devices and medical applications, high speed micro milling and micro drilling, etc. Furthermore, implementation tech- niques are presented focusing on： （a） plug-and-produce design principle and the associated smart control algo- rithms, （b） piezoelectric film and surface acoustic wave transducers to measure cutting forces in process, （c） critical cutting temperature control in real-time machining, （d） in- process calibration through machining trials, （e） FE-based design and analysis of smart cutting tools, and （f） applica- tion exemplars on adaptive smart machining.

Experimental Research on Effects of Process Parameters on Servo Scanning 3D Micro Electrical Discharge Machining

Servo scanning 3D micro electrical discharge machining (3D SSMEDM) is a novel and effective method in fabricating complex 3D micro structures with high aspect ratio on conducting materials. In 3D SSMEDM process, the axial wear of tool electrode can be compensated automatically by servo-keeping discharge gap, instead of the traditional methods that depend on experiential models or intermittent compensation. However, the effects of process parameters on 3D SSMEDM have not been reported up until now. In this study, the emphasis is laid on the effects of pulse duration, peak current, machining polarity, track style, track overlap, and scanning velocity on the 3D SSMEDM performances of machining efficiency, processing status, and surface accuracy. A series of experiments were carried out by machining a micro-rectangle cavity (900 μm×600 μm) on doped silicon. The experimental results were obtained as follows. Peak current plays a main role in machining efficiency and surface accuracy. Pulse duration affects obviously the stability of discharge state. The material removal rate of cathode processing is about 3/5 of that of anode processing. Compared with direction-parallel path, contour-parallel path is better in counteracting the lateral wear of tool electrode end. Scanning velocity should be selected moderately to avoid electric arc and short. Track overlap should be slightly less than the radius of tool electrode. In addition, a typical 3D micro structure of eye shape was machined based on the optimized process parameters. These results are beneficial to improve machining stability, accuracy, and efficiency in 3D SSMEDM.

Electrochemical Machining Analysis on Grid Cathode Composed of Square Cells

During the electrochemical machining (ECM), the cathodes designed by the existing methods are mainly unitary cathodes, which can be only used to produce the workpieces with the same shapes. However, there are few researches on designing cathodes for machining the different workpieces with the different surfaces. This paper presents the grid cathode composed of the square cells to produce the workpieces with different shapes. Three types of the square cells, 2.5 mm′2.5 mm, 3 mm′3 mm, and 4 mm′4 mm, are utilized to construct the plane, the slant, and the blade cathode. The material of the cathode and the anode is CrNi 18 Ti 9 , and the ingredient of electrolyte is 15% NaCl and 15% NaNO 3 . The machining equilibrium machining current and time are acquired and analyzed, the machining process and the workpiece quality are compared between using the grid cathode and the unitary cathode. Moreover, the machining errors on the workpiece surface are measured and analyzed, and the error reasons are traced and discussed to obtain the better surface quality of the workpiece. The experiment and analysis results show that the grid cathode can be used to manufacture the workpieces with complex shapes in certain range of the error. The workpiece quality improves with the size of the square cell being reduced, and if the square element is small enough, the workpiece quality is almost equal to the one machined by the unitary cathode. The proposed research realizes a single cathode machining the different workpieces with the different surfaces.

Approach for Polishing Diamond Coated Complicated Cutting Tool: Abrasive Flow Machining(AFM)

Lower surface roughness and sharper cutting edge are beneficial for improving the machining quality of the cut?ting tool, while coatings often deteriorate them. Focusing on the diamond coated WC?Co milling cutter, the abrasive flow machining(AFM) is selected for reducing the surface roughness and sharpening the cutting edge. Comparative cutting tests are conducted on di erent types of coated cutters before and after AFM, as well as uncoated WC?Co one, demonstrating that the boron?doped microcrystalline and undoped fine?grained composite diamond coated cutter after the AFM(AFM?BDM?UFGCD) is a good choice for the finish milling of the 6063 Al alloy in the present case, because it shows favorable machining quality close to the uncoated one, but much prolonged tool lifetime. Besides, compared with the micro?sized diamond films, it is much more convenient and e cient to finish the BDM?UFGCD coated cutter covered by nano?sized diamond grains, and resharpen its cutting edge by the AFM, owing to the lower initial surface roughness and hardness. Moreover, the boron incorporation and micro?sized grains in the underly?ing layer can enhance the film?substrate adhesion, avoid the rapid film removal in the machining process, and thus maximize the tool life(1040 m, four times more than the uncoated one). In general, the AFM is firstly proposed and discussed for post?processing the diamond coated complicated cutting tools, which is proved to be feasible for improving the cutting performance