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.

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.

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.

Feed Drive Based upon Linear Motor for Ultraprecision Turning Machine

The characteristics of several different linear motors have been investigated, and the feed drive system with linear motor instead of screw-nut mechanism has been built for a submicro ultraprecision turning machine. In the control system for the feed drive system arranged as "T", both P-position and PI-speed control loops are used. The feedback variable is obtained from a double frequecy laser interferometor. Experiments show that the feed drive with linear motor is simple in construction, and that its dynamics is better than others. So the machining accuracy of the workpiece machined has been successfully improved.

Ultra-precision machining of cerium-lanthanum alloy with atmosphere control in an auxiliary device

Cerium–lanthanum alloys are the main component of nickel–metal hydride batteries,and they are thus an important material in the greenenergy industry.However,these alloys have very strong chemical activity,and their surfaces are easily oxidized,leading to great difficulties in their application.To improve the corrosion resistance of cerium–lanthanum alloys,it is necessary to obtain a nanoscale surface with low roughness.However,these alloys can easily succumb to spontaneous combustion during machining.Currently,to inhibit the occurrence of fire,machining of this alloy in ambient air needs to be conducted at very low cutting speeds while spraying the workpiece with a large amount of cutting fluid.However,this is inefficient,and only a very limited range of parameters can be optimized at low cutting speeds;this restricts the optimization of other cutting parameters.To achieve ultraprecision machining of cerium–lanthanum alloys,in this work,an auxiliary machining device was developed,and its effectiveness was verified.The results show that the developed device can improve the cutting speed and obtain a machined surface with low roughness.The device can also improve the machining efficiency and completely prevent the occurrence of spontaneous combustion.It was found that the formation of a build-up of swarf on the cutting tool is eliminated with high-speed cutting,and the surface roughness(Sa)can reach 5.64 nm within the selected parameters.Finally,the oxidation processes of the cerium–lanthanum alloy and its swarf were studied,and the process of the generation of oxidative products in the swarf was elucidated.The results revealed that most of the intermediate oxidative products in the swarf were Ce^(3+),there were major oxygen vacancies in the swarf,and the final oxidative product was Ce^(4+).

Micro-optical fabrication by ultraprecision diamond machining and precision molding

Ultraprecision diamond machining and high volume molding for affordable high precision high performance optical elements are becoming a viable process in optical industry for low cost high quality microoptical component manufacturing. In this process, first high precision microoptical molds are fabricated using ultraprecision single point diamond machining followed by high volume production methods such as compression or injection molding. In the last two decades, there have been steady improvements in ultraprecision machine design and performance, particularly with the introduction of both slow tool and fast tool servo. Today optical molds, including freeform surfaces and microlens arrays, are routinely diamond machined to final finish without post machining polishing. For consumers, compression mold- ing or injection molding provide efficient and high quality optics at extremely low cost. In this paper, first ultrapreci- sion machine design and machining processes such as slow tool and fast too servo are described then both compression molding and injection molding of polymer optics are discussed. To implement precision optical manufacturing by molding, numerical modeling can be included in the future as a critical part of the manufacturing process to ensure high product quality.

Energy field-assisted high-speed dry milling green machining technology for difficult-to-machine metal materials

Energy field-assisted machining technology has the potential to overcome the limitations of machining difficult-to-machine metal materials,such as poor machinability,low cutting efficiency,and high energy consumption.High-speed dry milling has emerged as a typical green processing technology due to its high processing efficiency and avoidance of cutting fluids.However,the lack of necessary cooling and lubrication in high-speed dry milling makes it difficult to meet the continuous milling requirements for difficult-to-machine metal materials.The introduction of advanced energy-field-assisted green processing technology can improve the machinability of such metallic materials and achieve efficient precision manufacturing,making it a focus of academic and industrial research.In this review,the characteristics and limitations of high-speed dry milling of difficult-to-machine metal materials,including titanium alloys,nickel-based alloys,and high-strength steel,are systematically explored.The laser energy field,ultrasonic energy field,and cryogenic minimum quantity lubrication energy fields are introduced.By analyzing the effects of changing the energy field and cutting parameters on tool wear,chip morphology,cutting force,temperature,and surface quality of the workpiece during milling,the superiority of energy-field-assisted milling of difficult-to-machine metal materials is demonstrated.Finally,the shortcomings and technical challenges of energy-field-assisted milling are summarized in detail,providing feasible ideas for realizing multi-energy field collaborative green machining of difficult-to-machine metal materials in the future.

Novel Batch Polishing Method of Ceramic Cutting Inserts for Reducing Tool Wear

Ceramic cutting inserts are a type of cutting tool commonly used in high-speed metal cutting applications.However,the wear of these inserts caused by friction between the workpiece and cutting inserts limits their overall effectiveness.In order to improve the tool life and reduce wear,this study introduces an emerging method called magnetic field-assisted batch polishing(MABP)for simultaneously polishing multiple ceramic cutting inserts.Several polishing experiments were conducted under different conditions,and the wear characteristics were clarified by cutting S136H steel.The results showed that after 15 min of polishing,the surface roughness at the flank face,edge,and nose of the inserts was reduced to below 2.5 nm,6.25 nm,and 45.8 nm,respectively.Furthermore,the nose radii of the inserts did not change significantly,and there were no significant changes in the weight percentage of elements before and after polishing.Additionally,the tool life of the batch polished inserts was found to be up to 1.75 times longer than that of unpolished inserts.These findings suggest that the MABP method is an effective way to mass polish ceramic cutting inserts,resulting in significantly reduced tool wear.Furthermore,this novel method offers new possibilities for polishing other tools.

Magnetic field-assisted batch polishing method for the mass production of precision optical glass components

The demand for optical glass has been rapidly increasing in various industries,where an ultra-smooth surface and form accuracy are critical for the functional elements of the applications.To meet the high surface-quality requirements,a polishing process is usually adopted to finish the optical glass surface to ensure an ultra-smooth surface and eliminate sub-surface damage.However,current ultra-precision polishing processes normally polish workpieces individually,leading to a low production efficiency and high polishing costs.Current mass-finishing methods cannot be used for optical glasses.Therefore,magnetic-field-assisted batch polishing(MABP)was proposed in this study to overcome this research gap and provide an efficient and cost-effective method for industrial use.A series of polishing experiments were conducted on typical optical components under different polishing parameters to evaluate the polishing performance of MABP on optical glasses.The results demonstrated that MABP is an efficient method to simultaneously polish multiple lenses while achieving a surface roughness,indicated by the arithmetic mean height(Sa),of 0.7 nm and maintained a sub-micrometer surface form for all the workpieces.In addition,no apparent sub-surface damage was observed,indicating the significant potential for the high-quality rapid polishing of optical glasses.The proposed method is highly competitive compared to the current optical polishing methods,which has the potential to revolutionize the polishing process for small optics.

ELID磨削──硬脆材料精密和超精密加工的新技术

金属基超硬磨料砂轮在线电解修整（ＥｌｅｃｔｒｏｌｙｔｉｃＩｎｐｒｏｃｅｓＤｒｅｓｉｎｇ，简称ＥＬＩＤ）磨削技术是国外近年发展起来的一种硬脆材料精密和超精密加工新技术。本文介绍了ＥＬＩＤ磨削技术的基本原理、工艺特点和国内外研究应用情况。应用ＥＬＩＤ磨削技术。

精密加工和超精密加工技术综述

论述了精密加工和超精密加工技术的范畴、加工方法、系统结构及其在先进制造技术中的作用和地位；分析了21世纪初期对它的需求和技术发展趋势，并提出了相应的技术发展前沿，归总了技术发展特点。

现代超精密加工技术的概况及应用

对现代超精密加工技术的发展现状、地位以及在相关领域的应用进行了论述。并对超精密加工设备以及误差补 偿技术方面也作了阐述。

分子动力学仿真技术在超精密加工领域中的应用

分子动力学仿真在超精密及微细加工中的作用已显示出良好的前景 ,较系统地描述了分子动力学中采用的势函数 ,仿真过程中的切屑形成、切削力、切削温度及表面质量 ,仿真算法与边界条件等内容 ;并结合实际分析了仿真图形的物理意义。最后指出了存在的问题和改进措施。

超光滑光学表面加工技术

现代科学技术的发展，在许多领域中提出了加工超光滑表面的要求。这种表面不仅要具备较高的面形精度和极低的表面粗糙度，同时要具有完整的表面晶格排布，消除加工损伤层。近年来国际出现了不少成功的超光滑表面加工技术，可以实现表面粗糙度小于１ｎｍ，面形精度优于３０ｎｍ。本文介绍了超光滑表面的主要应用领域；从去除机理的角度讨论了ＢＦＰ抛光、Ｔｅｆｌｏｎ抛光、离子束加工、ＰＡＣＥ加工、浮法抛光、延展性磨削等六种有代表性的超光滑表面加工技术；并对国内情况作了简单分析。

航天铝基复合材料零部件超精密加工技术研究

针对航天高碳化硅铝基复合材料零部件采用聚晶金刚石PCD刀具进行了超精密车削加工试验,用原子力显微镜AFM和扫描电子显微镜对其进行了检测,分析了零部件表面粗糙度值的大小及影响因素、SiCw变形破坏机理、已加工表面微观结构及加工变质层特性。结果表明,超精密车削高碳化硅铝基复合材料零部件可以获得超精密级加工表面(如Ra11.5nm);超精密车削过程中SiCw存在着三种主要变形破坏机理:直接剪断型、拔出型和压入型,且以直接剪断型为主。直接剪断的SiCw对表面粗糙度值影响最小,而后二者是影响表面粗糙度值达到超精密级的主要障碍;超精密加工零部件表面仍会产生很薄的加工变质层。

小口径非球面加工技术及装备综述

小口径非球面零件是一种非常重要的光学零件。介绍了国内外小口径非球面超精密加工技术的发展现状和装备。对单点金刚石车削、超精密磨削、透镜成型、超精密铣削和特种加工技术进行了综述。指出了小口径非球面加工的发展趋势和产业化需要解决的问题。

超精密加工机床的关键部件技术

论述了亚微米级超精密加工机床的主轴、直线导轨、进给与微量进给、隔振与恒温等关键元部件的设计原理、实施方案，及其在ＨＣＭ－Ⅰ超精密加工机床中的应用。

超声波磁流变复合抛光中几种工艺参数对材料去除率的影响

提出了一种光学抛光的新方法——超声波磁流变复合抛光。介绍了该抛光方法的基本原理和实验装置,进行了超声波磁流变复合抛光实验,采用轮廓仪实测了光学玻璃超声波磁流变抛光材料去除轮廓曲线。通过该项工艺实验,研究了五种工艺参数(磁场强度、超声振幅、抛光工具头与工件的间隙、抛光工具头转速、工件转速)对光学玻璃材料去除率的影响。在一定实验条件下,获得的材料去除率为0.139μm/min,并获得了超声波磁流变复合抛光工艺参数与材料去除率的关系曲线,得出了光学玻璃超声波磁流变复合抛光的材料去除规律。

非球面曲面光学零件超精密加工装备与技术

“Nanosys_30 0非球面曲面超精密复合加工系统”是“九五”重点预研课题—“非球面曲面的超精密加工与测量技术”的主要研究成果。重点对非球面曲面光学零件超精密加工机床 ,非球面曲面光学零件超精密加工工艺 ,非球面曲面光学零件超精密测量技术进行了研究。其主要技术成果有 :非球面超精密复合加工系统综合设计和制造技术 ,高速超精密空气静压主轴系统 ,超精密闭式液体静压导轨系统 ,高速超精密空气静压磨头电主轴系统 ,开放式高性能数控系统集成技术等。系统的精度检测和工艺实验表明其研究水平进入了国际先进行列。