Development and Prospectives of Ultra-High-Speed Grinding Technology

Ultra-high-speed grinding(UHSG)is a significant and powerful machining method in view of the enhanced productivity and precision demands.Previous researches regarding formation mechanisms and crucial technologies are comprehensively and thoroughly summarized to highlight state-of-art technology of UHSG.On the basis of the interdependence between process and machine innovations,theoretically,grinding mechanisms in strain hardening,strain rate strengthening,thermal softening,size effect and process characteristics need more in-depth studies to clarify the dominance of UHSG.Technically,CFRP wheel integrating with the brazed bonding has a prominent advantage in bonding strength and grit′s configuration over vitrified bonding,which would be superior in UHSG.Furthermore,external high pressure cooling combining with inner jet cooling methods,accompanied by scraper plates to alleviate the effect of air boundary,are crucial and practical measures for realizing effective cooling in UHSG.Grinding processes,especially those being related to grinding parameters and precise in-process measuring approaches,are also prerequisite for fitting and investigation of UHSG.

Towards Sustainable Grinding of Difficult-to-Cut Alloys-A Holistic Review and Trends

Grinding,a critical precision machining process for difficult-to-cut alloys,has undergone continual technological advancements to improve machining efficiency.However,the sustainability of this process is gaining heightened attention due to significant challenges associated with the substantial specific grinding energy and the extensive heat generated when working with difficult-to-cut alloys,renowned for their exceptional physical and mechanical properties.In response to these challenges,the widespread application of massive coolant in manufacturing industries to dissipate grinding heat has led to complex post-cleaning and disposal processes.This,in turn,has resulted in issues such as large energy consumption,a considerable carbon footprint,and concerns related to worker health and safety,which have become the main factors that restrict the development of grinding technology.This paper provides a holistic review of sustainability in grinding difficult-to-cut alloys,encompassing current trends and future directions.The examination extends to developing grinding technologies explicitly tailored for these alloys,comprehensively evaluating their sustainability performance.Additionally,the exploration delves into innovative sustainable technologies,such as heat pipe/oscillating heat pipe grinding wheels,minimum quantity lubrication,cryogenic cooling,and others.These groundbreaking technologies aim to reduce dependence on hazardous coolants,minimizing energy and resource consumption and carbon emissions associated with coolant-related or subsequent disposal processes.The essence of these technologies lies in their potential to revolutionize traditional grinding practices,presenting environmentally friendly alternatives.Finally,future development trends and research directions are put forward to pursue the current limitation of sustainable grinding for difficult-to-cut alloys.This paper can guide future research and development efforts toward more environmentally friendly grinding operations by understanding the current state of sustainable grinding and identifying emerging trends.

The Effects of the Geometry of a Current Collector with an Equal Open Ratio on Output Power of a Direct Methanol Fuel Cell

The open ratio of a current collector has a great impact on direct methanol fuel cell(DMFC)performance.Although a number of studies have investigated the influence of the open ratio of DMFC current collectors,far too little attention has been given to how geometry(including the shape and feature size of the flow field)affects a current collector with an equal open ratio.In this paper,perforated and parallel current collectors with an equal open ratio of 50%and different feature sizes are designed,and the corresponding experimental results are shown to explain the geometry effects on the output power of the DMFC.The results indicate that the optimal feature sizes are between 2 and 2.5 mm for both perforated and parallel flow field in the current collectors with an equal open ratio of 50%.This means that for passive methanol fuel cells,to achieve the highest output power,the optimal feature size of the flow field in both anode and cathode current collectors is between 2 and 2.5 mm under the operating mode of this experiment.The effects of rib and channel position are also investigated,and the results indicate that the optimum pattern depends on the feature sizes of the flow field.

Identification of the key thermal points on machine tools by grouping and optimizing variables

The grouping and optimization approach to identify the key thermal points on machine tools is studied.To solve the difficulty in grouping because of the high correlated variables from distinct groups,the variables grouping technique is improved.Temperature variables are sorted according to their relativities with the thermal errors.The representative temperature variables are determined by analyzing the variable correlation in sort order and removing the other variables in the same group.Considering the diverse effect of importing the different variables on thermal error model,the method of variable combination optimization is improved.Regression models made up of different combination of representative temperature variables are evaluated by the index of both the determined coefficient and the average residual squares to select the combination of the temperature variables.For the machine tools with complicated structures which need more initial temperature measuring points the improvement is demanded.The improved approach is applied to a precision horizontal machining center to identify the key thermal points.Experimental results show that the proposed approach is capable of avoiding the high correlation among the different groups' variables,effectively reducing the number of the key thermal points without depressing the prediction accuracy of the thermal error model for machine tools.

In-situ deposition of apatite layer to protect Mg-based composite fabricated via laser additive manufacturing

Biodegradable magnesium(Mg) and its alloy show huge potential as temporary bone substitute due to the favorable biocompatibility and mechanical compatibility. However, one issue deserves attention is the too fast degradation. In this work, mesoporous bioglass(MBG)with high pore volume(0.59 cc/g) and huge specific surface area(110.78 m^(2)/g) was synthesized using improved sol-gel method, and introduced into Mg-based composite via laser additive manufacturing. Immersion tests showed that the incorporated MBG served as powerful adsorption sites, which promoted the in-situ deposition of apatite by successively adsorbing Ca2+and HPO42-. Such dense apatite film acted as an efficient protection layer and enhanced the corrosion resistance of Mg matrix, which was proved by the electrochemical impedance spectroscopy measurements. Thereby, Mg based composite showed a significantly decreased degradation rate of 0.31 mm/year. Furthermore,MBG also improved the mechanical properties as well as cell behavior. This work highlighted the advantages of MBG in the fabrication of Mg-based implant with enhanced overall performance for orthopedic application.

Precision wire electrochemical machining of thick structures in powder superalloy René88DT using a partially insulated tube electrode

Wire electrochemical machining(WECM)is a potential method for manufacturing macrostructures from difficult-to-cut materials,such as turbine slots,with good surface integrity and low costs.In this study,a novel tube electrode with array holes in the front and insulation in the back was applied using WECM to improve the machining precision and efficiency.Additionally,assisted by an immersion electrolyte and axial flushing,the electrolyte-deficient gap was supplemented to achieve the cutting of a very thick workpiece.The simulation results indicated that this method could effectively reduce the machining gap and improve the uniformity of the electric-and flow-field distributions.Experiments verified that when the uninsulated range(machining angle)was reduced from 360°to 90°,the side machining gap was reduced from 462.5µm to 175µm.Finally,using optimized machining parameters,array slits with gaps as small as(175±10)μm were machined on a powder superalloy René88DT sample with a thickness of 10 mm at a feed rate of 16µm/s.The feasibility of fabricating complex profiles using this method was verified using a self-designed servo device.

A Lay-up-Oriented CFRP-Substrate Metamaterial Absorber with High Insensitivity to Polarization

Metamaterial absorbers with carbon fiber reinforced polymer(CFRP)substrates,which are called metaCFRPs,have recently gained recognition for their excellent mechanical and electromagnetic performance.Different from traditional metamaterial absorbers with an isotropic substrate,meta-CFRPs with a highly anisotropic CFRP substrate are facing challenges in acquiring polarization-insensitive absorption.Here,a lay-up-oriented structure design method is proposed to solve this problem.Considering the lay-up configuration of CFRP laminates,metallic patterns are designed under corresponding polarization angles and then united together to form an integral structure.A meta-CFRP with a typical CFRP lay-up configuration([0°/45°/90°/-45°]3s)is designed and tested.The experimental results exhibit over 99%microwave absorptivity at 2.44 GHz for all polarization angles.The maximum shift among the resonance peaks of the curves at all polarization angles is only 0.021 GHz.Further studies show that when there are cross-ply laminates in the first few layers of the CFRP substrate,the lay-up-oriented design method can be effectively simplified by ignoring the subsequent lay-up orientations after the first cross-ply layers.Our method can not only provide an effective way for acquiring polarization-insensitive microwave response on meta-CFRPs but also be expected to be promoted to metamaterial absorbers with other anisotropic materials.

Energy-efficient Approach to Minimizing the Energy Consumption in An Extended Job-shop Scheduling Problem

The traditional production planning and scheduling problems consider performance indicators like time, cost and quality as optimization objectives in manufacturing processes. However, environmentally-friendly factors like energy consumption of production have not been completely taken into consideration. Against this background, this paper addresses an approach to modify a given schedule generated by a production plarming and scheduling system in a job shop floor, where machine tools can work at different cutting speeds. It can adjust the cutting speeds of the operations while keeping the original assignment and processing sequence of operations of each job fixed in order to obtain energy savings. First, the proposed approach, based on a mixed integer programming mathematical model, changes the total idle time of the given schedule to minimize energy consumption in the job shop floor while accepting the optimal solution of the scheduling objective, makespan. Then, a genetic-simulated annealing algorithm is used to explore the optimal solution due to the fact that the problem is strongly NP-hard. Finally, the effectiveness of the approach is performed small- and large-size instances, respectively. The experimental results show that the approach can save 5%-10% of the average energy consumption while accepting the optimal solution of the makespan in small-size instances. In addition, the average maximum energy saving ratio can reach to 13%. And it can save approximately 1%-4% of the average energy consumption and approximately 2.4% of the average maximum energy while accepting the near-optimal solution of the makespan in large-size instances. The proposed research provides an interesting point to explore an energy-aware schedule optimization for a traditional production planning and scheduling problem.

Numerical Calculation and Experimental Research on Residual Stresses in Precipitation-hardening Layer of NAK80 Steel for Shot Peening

Shot peening can improve fatigue strength of materials by creating compressive residual stress field in their surface layers,and offers a protection against crack initiation and propagation,corrosion,etc.And fatigue fracture and stress corrosion cracking of NAK80 steel parts are improved effectively.Currently there lacks in-depth research in which the beneficial effect of the residual stress may be offset by the surface damage associated with shot peening,especially in terms of the research on the effective control of shot peening intensity.In order to obtain the surface residual stress field of NAK80 steel after shot peening,the samples are shot peened by pneumatic shot peening machine with different rules.The residual stress in the precipitation-hardening layer of NAK80 steel is measured before and after a shot peening treatment by X-ray diffraction method.In order to obtain true residual stress field,integral compensation method is used to correct results.By setting up analytical model of the residual stress in the process of shot peening,the surface residual stress is calculated after shot peening,and mentioning the reason of errors occurred between calculated and experimental residual stresses,which is mainly caused by the measurement error of the shoot arc height.At the same time,micro hardness,microstructure and roughness in the precipitation-hardening layer of NAK80 steel before and after shot peening were measured and surveyed in order to obtain the relation between shot peening strength and surface quality in the precipitation-hardening layer.The results show that the surface quality of NAK80 steel is significantly improved by shot peening process.The over peening effect is produced when the shot peening intensity is too high,it is disadvantageous to improve sample＇s surface integrity,and leading to reduce the fatigue life.When arc high value of optimal shot peening is 0.40 mm,the surface quality is the best,and the depth of residual stress in the precipitation-hardening layer reaches to about 450 μm.Numerical calculation is very useful to define the process parameters when a specific residual stress profile is intended,either to quantify the benefits on a specific property like fatigue life or to help on modeling a forming process like shot peen forming.In particular,the proposed parameter optimization in the progress of shot peening and effective control of the surface texture provide new rules for the quantitative evaluations of shot peening surface modification of NAK80 steel.

Mechanism of brittle-ductile transition of a glass-ceramic rigid substrate

The hardness, elastic modulus, and scratch resistance of a glass-ceramic rigid substrate were measured by nanoindentation and nanoscratch, and the fracture toughness was measured by indentation using a Vickers indenter. The results show that the hardness and elastic modulus at a peak indentation depth of 200 nm are 9.04 and 94.70 GPa, respectively. These values reflect the properties of the glass-ceramic rigid substrate. The fracture toughness value of the glass-ceramic rigid substrate is 2.63 MPa？m1/2. The material removal mechanisms are seen to be directly related to normal force on the tip. The critical load and scratch depth estimated from the scratch depth profile after scratching and the friction profile are 268.60 mN and 335.10 nm, respectively. If the load and scratch depth are under the critical values, the glass-ceramic rigid substrate will undergo plastic flow rather than fracture. The formula of critical depth of cut described by Bifnao et al. is modified based on the difference of critical scratch depth

Microstructure and Oxidation Behaviors of Nano-particles Strengthened NiCoCrAlY Cladded Coatings on Superalloys

Nano-particles which can largely improve the microstructure and oxidation resistance of materials are often used as a strengthening component in metal matrix composites. However, few studies were reported on its application in the bond coat of duplex structure thermal barrier coating（TBC）. Three kinds of NiCoCrAlY coatings strengthened by different nano-particles with the same addition （1%, mass fraction） were prepared by the laser cladding technique on Ni-based superalloy substrates, aiming to study the effects of the nano-particles on microstructure and oxidation resistance of NiCoCrAlY coatings （the bond coat of the duplex structure thermal barrier coatings）. Scanning electron microscope （SEM）, X-ray diffractometer（XRD） and thermogravimetry were employed to investigate their morphologies, phases and cyclic oxidation behaviors in atmosphere at 1 050℃, compared with the coating without nano-particles. With the addition of nano-particles, the growth pattern of the grains at the interface changed from epitaxial growth to non-epitaxial growth or part-epitaxial growth; slender dendrites were broken and cellularized; cracks and pores were restrained; and the oxidation weight-gain and the stripping resistance of the oxide scale were improved as well. Among the three kinds of nano-particles, the SiC nano-particles showed the most improvement on microstructure, while the CeO2 nano-particles were insufficient, but its effects on the oxidation resistance are the same as those of the SiC nano-particles. Based on the discussions of the influence mechanism, it is believed that CeO2 nano-particles would show better improvement than SiC nano-particles if the proper amount is added and the proper preparation technique of micro-nanometer composite powders is adopted, with the synergistic action of nanometer effect and reactive element effect.

Microstructure of nanometer Al_2O_3 dispersion strengthened Ni-based high-temperature protective coatings by laser cladding

The nanometer Al2O3 dispersion strengthened NiCoCrAlY high-temperature protective coatings by crosscurrent CO2 laser on Ni-based superalloy GH4033 were produced. Microscopic morphologies, phase constitutions of cladding coatings and distribution of nano-Al2O3 particles were examined using SEM and XRD. The results show that the interface grains, after adding proper nano-Al2O3, grow from epitaxial to non-epitaxial shape gradually, and the columnar dendrites become thinner and denser with cellular shape. Cracks in the substrate close to the interface are eliminated. Moreover, dispersive nano-Al2O3 particles mainly distribute around cellular substructure and on grain-boundaries, which prevents the diffusion of alloying elements and restrains the formation of new phase. There is a critical value of nano-Al2O3 addition, and the most suitable content of nano-Al2O3 is 1% (mass fraction) in this experimental conditions. The "nanometer effect" of nano-Al2O3 particles plays an important role in the improvement of coating microstructure.

Effect of cerium on microstructure,wetting and mechanical properties of Ag-Cu-Ti filler alloy

Effect of cerium on microstructure,mechanical and wetting properties of Ag-Cu-Ti filler alloy was researched with optical microscopy,scanning electron microscopy and X-ray diffraction.The results indicated that addition of cerium accelerated alloying of the filler alloy,enlarged supercooled region,caused microstructural refinement and dispersed distribution of intermetallic compounds.It resulted in the increase in microhardness and shear strength of Ag-Cu-Ti filler alloy.At the same time,cerium improved wet...

Preparation and characterization of nanostructured Al_2O_3-13wt.%TiO_2 ceramic coatings by plasma spraying

Nanostructured and conventional Al2O3-13wt.%TiO2 ceramic coatings were prepared by plasma spraying with nanostructured agglomerated and conventional powders, respectively. The microstructure and microhardness of the coatings were investigated using scanning electron microscopy （SEM）, energy dispersive spectroscopy （EDS）, and microhardness measurement. Meanwhile, the friction and wear behaviors were analyzed and compared using a ball-on-disk tribometer. The results show that the conventional coating has lamellar stacking characteristic and has some pores. However, the nanostructured coating shows a bimodal microstructure, which is composed of both fully melted regions and partially melted regions. According to the microstructural difference, the partially melted regions can be divided into liquid-phase sintered regions （a three-dimensional net or skeleton-like structure： Al2O3-rich submicron particles embedded in the TiO2-rich matrix） and solid-phase sintered regions （remained nanoparticles）. The microstructural characteristics of the liquid-phase sintered region are formed due to the selective melting of TiO2 nanoparticles during plasma spraying. On the other hand, the TiO2 and Al2O3 nanoparticles of the solid-phase sintered regions are all unmelted during plasma spraying. Due to the existence of nanostructured microstructures, the nanostructured coating has a higher microhardness, a lower friction coefficient, and a better wear resistance than the conventional coating.

Optimization of Polishing Parameters with Taguchi Method for LBO Crystal in CMP

Chemical mechanical polishing （CMP） was used to polish Lithium triborate （LiB3O5 or LBO） crystal. Taguchi method was applied for optimization of the polishing parameters. Material removal rate （MRR） and surface roughness are considered as criteria for the optimization. The polishing pressure, the abrasive concentration and the table velocity are important parameters which influence MRR and surface roughness in CMP of LBO crystal. Experiment results indicate that for MRR the polishing pressure is the most significant polishing parameter followed by table velocity; while for the surface roughness, the abrasive concentration is the most important one. For high MRR in CMP of LBO ctystal the optimal conditions are： pressure 620 g/cm^2, concentration 5.0 wt pct, and velocity 60 r/min, respectively. For the best surface roughness the optimal conditions are： pressure 416 g/cm^2, concentration 5.0 wt pct, and velocity 40 r/min, respectively. The contributions of individual parameters for MRR and surface roughness were obtained.

A bifunctional bone scaffold combines osteogenesis and antibacterial activity via in situ grown hydroxyapatite and silver nanoparticles

Hydroxyapatite(HA)nanoparticles and silver(Ag)nanoparticles are expected to enable desirable bioactivity and antibac-terial properties on biopolymer scaffolds.Nevertheless,interfacial adhesion between HA/Ag and the biopolymer is poor due to the large physicochemical differences between these components.In this study,poly L-lactic acid(PLLA)powder was first surface-modified with bioactive polydopamine(PDA)in an alkaline environment.Next,HA and Ag nanoparticles were grown in situ on the PDA-coated PLLA powder,which was then adhered to the porous bone scaffold using a selective laser-sintering process.Results showed that HA and Ag nanoparticles were homogenously distributed in the matrix,with enhanced mechanical properties.Simulated body fluid bioactivity tests showed that the in situ grown HA-endowed scaffold shows excellent bioactivity.In vitro tests confirmed that the scaffold exhibits favorable biocompatibility with human umbilical cord mesenchymal stem cells,as well as strong antibacterial activity against Gram-negative Escherichia coli.Furthermore,in vivo assays indicated that the scaffold promoted bone generation,with a new bone area fraction of 71.8%after 8 weeks’implantation,without inflammation.

Influence of Shim Layers on Progressive Failure of a Composite Componentin Composite-Aluminum Bolted Joint in Aerospace Structural Assembly

The influence of varying shim layers on the progressive damage/failure of a composite component in a bolted composite-aluminum aerospace structural assembly was investigated using a non-linear three-dimensional(3 D)structural solid elements assembled model of a carbon fiber-reinforced polymer(CFRP)-aluminum single-lap joint with a titanium(Ti-6 Al-4 V)fastener and a washer generated with the commercial finite element(FE)software package,ABAQUS/Standard.A progressive failure algorithm written in Fortran code with a set of appropriate degradation rules was incorporated as a user subroutine in ABAQUS to simulate the non-linear damage behavior of the composite component in the composite-aluminum bolted aerospace structure.The assembled 3 DFE model simulated,as well as the specimen for the experimental testing consisted of a carbon-epoxy IMS-977-2 substrate,aluminum alloy 7075-T651 substrate,liquid shim(Hysol EA 9394),solid peelable fiberglass shim,a titanium fastener,and a washer.In distinction to previous investigations,the influence of shim layers(liquid shim and solid peelable fiberglass shim)inserted in-between the faying surfaces(CFRP and aluminum alloy substrates)were investigated by both numerical simulations and experimental work.The simulated model and test specimens conformed to the standard test configurations for both civil and military standards.The numerical simulations correlated well with the experimental results and it has been found that:(1)The shimming procedure as agreed upon by the aerospace industry for the resolution of assembly gaps in bolted joints for composite materials is the same for a composite-aluminum structure;liquid shim series(0.3,0.5 and 0.7 mm thicknesses)prolonged the service life of the composite component whereas a solid peelable fiberglass shim most definitely had a better influence on the 0.9 assembly gap compared with the liquid shim;(2)The shim layers considerably influenced the structural strength of the composite component by delaying its ultimate failure thereby increasing its service life;and(3)Increasing the shim layer′s thickness led to a significant corresponding effect on the stiffness but with minimal effect on the ultimate load.

CUTTING REGULARITY AND DISCHARGE CHARACTERISTICS BY USING COMPOSITE COOLING LIQUID IN WIRE CUT ELECTRICAL DISCHARGE MACHINE WITH HIGH WIRE TRAVELING SPEED

The analysis of cutting regularity is provided through using and comparing two typical cooling liquids. It is proved that cutting regularity is greatly affected by cooling liquid＇s washing ability. Discharge characteristics and theoretic analysis between two electrodes are also discussed based on discharge waveform. By using composite cooling liquid which has strong washing ability, the efficiency in the first stable cutting phase has reached more than 200 mm^2/min, and the roughness of the surface has reached Ra〈0.8 μm after the fourth cutting with more than 50 mm^2/min average cutting efficiency. It is pointed out that cutting situation of the wire cut electrical discharge machine with high wire traveling speed （HSWEDM） is better than the wire cut electrical discharge machine with low wire traveling speed （LSWEDM） in the condition of improving the cooling liquid washing ability. The machining indices of HSWEDM will be increased remarkably by using the composite cooling liquid.

机械合金化与激光烧结制备铁锌过饱和固溶体及其降解行为研究

过慢的降解限制铁的骨植入应用,锌固溶在铁基体中有望加速其降解。首先利用机械合金化制备铁锌过饱和固溶体粉末。在合金化过程中,机械力的作用使得粉末颗粒间反复焊合,减小了溶质原子扩散距离,同时出现大量晶格缺陷,进一步促进了溶质原子的扩散。随后,利用激光烧结技术把粉末固化成型,烧结过程中粉末部分熔化并快速凝固,从而维持了原有过饱和固溶体结构。实验结果表明,所制备铁锌合金的腐蚀电位降低,腐蚀速率提高到0.112 mm/year,且具有良好的生物相容性。这项工作展现了机械合金化与激光烧结组合工艺在制备高性能可降解铁锌植入物方面的巨大潜力。

Theoretical and Experimental Investigation of Laser Milling Assisted with Jet Electrochemical Machining

In laser milling assisted with jet electrochemical machining(LMAJECM),the source of energy is a pulsed laser beam aligned coaxially with a jet of electrolyte,which focuses optical energy on the surface of workpiece.The impact of jet of electrolyte develops a state-of-art work to perform operations such as electrolytic etching,effective cooling,and transportation of debris.Therefore,a special jet cell is designed to obtain stable jet as to be a kind of noncontact tool,i.e.,electrode.According to the theoretical model of on-off pulse time process,laser machining and electrolytic anodization are simulated by finite element analysis(FEA)method.Grooves on a 0.5mm thick 321 stainless steel sheet produced by LMAJECM is performed with pulsed Nd:YAG laser at the second harmonic wavelength.Compared with laser milling under ambient atmosphere conditions,the recast layer and burrs are effectively diminished.And the accuracy of depth is dedicated to laser milling,whilst that of width is dominated by jet electrochemical machining.It is demonstrated that LMAJECM can be a highly potential approach for fabricating 3-D micro components.