Friction behaviors in the metal cutting process:state of the art and future perspectives

Material removal in the cutting process is regarded as a friction system with multiple input and output variables.The complexity of the cutting friction system is caused by the extreme conditions existing on the tool–chip and tool–workpiece interfaces.The critical issue is significant to use knowledge of cutting friction behaviors to guide researchers and industrial manufacturing engineers in designing rational cutting processes to reduce tool wear and improve surface quality.This review focuses on the state of the art of research on friction behaviors in cutting procedures as well as future perspectives.First,the cutting friction phenomena under extreme conditions,such as high temperature,large strain/strain rates,sticking–sliding contact states,and diverse cutting conditions are analyzed.Second,the theoretical models of cutting friction behaviors and the application of simulation technology are discussed.Third,the factors that affect friction behaviors are analyzed,including material matching,cutting parameters,lubrication/cooling conditions,micro/nano surface textures,and tool coatings.Then,the consequences of the cutting friction phenomena,including tool wear patterns,tool life,chip formation,and the machined surface are analyzed.Finally,the research limitations and future work for cutting friction behaviors are discussed.This review contributes to the understanding of cutting friction behaviors and the development of high-quality cutting technology.

Geometric Accuracy and Energy Absorption Characteristics of 3D Printed Continuous Ramie Fiber Reinforced Thin-Walled Composite Structures

The application of continuous natural fibers as reinforcement in composite thin-walled structures offers a feasible approach to achieve light weight and high strength while remaining environmentally friendly.In addition,additive manufacturing technology provides a favorable process foundation for its realization.In this study,the printability and energy absorption properties of 3D printed continuous fiber reinforced thin-walled structures with different configurations were investigated.The results suggested that a low printing speed and a proper layer thickness would mitigate the printing defects within the structures.The printing geometry accuracy of the structures could be further improved by rounding the sharp corners with appropriate radii.This study successfully fabricated structures with vari-ous configurations characterized by high geometric accuracy through printing parameters optimization and path smoothing.Moreover,the compressive property and energy absorption characteristics of the structures under quasi-static axial compression were evaluated and compared.It was found that all studied thin-walled structures exhibited progressive folding deformation patterns during compression.In particular,energy absorption process was achieved through the combined damage modes of plastic deformation,fiber pullout and delamination.Furthermore,the com-parison results showed that the hexagonal structure exhibited the best energy absorption performance.The study revealed the structure-mechanical property relationship of 3D printed continuous fiber reinforced composite thin-walled structures through the analysis of multiscale failure characteristics and load response,which is valuable for broadening their applications.

Plastic Flow Modeling of Ti-5 Al-2 Sn-2 Zr-4 Mo-4 Cr Alloy at Elevated Temperatures and High Strain Rates

The true stress-sWain relationships of Ti-5A1-2Sn-2Zr-4Mo-4Cr（TC17） alloy with a wide range of strain rates were investigated by tmiaxial quasi-static and dynamic compression tests, respectively. Quasi- static compression tests were carried out with Instron 8874 test machine, while dynamic compression tests were performed with the split Hopkinson pressure bar （SHPB） which was installed with heating device and synchro- assembly system. The dynamic mechanical behaviors tests of TC17 were carded out from room temperature to 800 ℃ at intervals of 200 ℃ and at high sWain rates （5 500-1 9200 s-l）. The stress-strain curves considering temperature-sWain rate coupling actions were obtained. The Johnson-Cook constitutive model was developed through data fitting of the stress-sWain curves. The material constants in the developed constitutive model can be determined using isothermal and adiabatic stress-strain curves at different strain rates. The Johnson-Cook constitutive model provided satisfied prediction of the plastic flow stress for TC17 alloy.

Hydrodynamic Cavitation Enhanced SR-Aops Degradation of Organic Pollutants in Water:A Review

SR-AOP(sulfate radical advanced oxidation process)is a novel water treatment method able to eliminate refractory organic pollutants.Hydrodynamic cavitation(HC)is a novel green technology,that can effectively produce strong oxidizing sulfate radicals.This paper presents a comprehensive review of the research advancements in these fields and a critical discussion of the principal factors influencing HC-enhanced SR-AOP and the mechanisms of synergistic degradation.Furthermore,some insights into the industrial application of HC/PS are also provided.Current research shows that this technology is feasible at the laboratory stage,but its application on larger scales requires further understanding and exploration.In this review,some attention is also paid to the design of the hydrodynamic cavitation reactor and the related operating parameters.

Review on Stress Corrosion and Corrosion Fatigue Failure of Centrifugal Compressor Impeller

Corrosion failure,especially stress corrosion cracking and corrosion fatigue,is the main cause of centrifugal compressor impeller failure.And it is concealed and destructive.This paper summarizes the main theories of stress corrosion cracking and corrosion fatigue and its latest developments,and it also points out that existing stress corrosion cracking theories can be reduced to the anodic dissolution（AD）,the hydrogen-induced cracking（HIC）,and the combined AD and HIC mechanisms.The corrosion behavior and the mechanism of corrosion fatigue in the crack propagation stage are similar to stress corrosion cracking.The effects of stress ratio,loading frequency,and corrosive medium on the corrosion fatigue crack propagation rate are analyzed and summarized.The corrosion behavior and the mechanism of stress corrosion cracking and corrosion fatigue in corrosive environments,which contain sulfide,chlorides,and carbonate,are analyzed.The working environments of the centrifugal compressor impeller show the behavior and the mechanism of stress corrosion cracking and corrosion fatigue in different corrosive environments.The current research methods for centrifugal compressor impeller corrosion failure are analyzed.Physical analysis,numerical simulation,and the fluid-structure interaction method play an increasingly important role in the research on impeller deformation and stress distribution caused by the joint action of aerodynamic load and centrifugal load.

Heat Transfer and Resistance Characteristics of Conical Spiral Tube Bundle Based on Field Synergy Principle

Conical spiral tube bundle are universally used in heat transfer enhancement in heat exchangers.The heat transfer and resistance of the tube bundle are affected greatly by the conical structure,so the analysis of it is necessary.In order to a further evaluation,the heat transfer and resistance characteristics of conical spiral tube bundle are investigated with regression analysis based on numerical simulation data.The correlations of heat transfer and pressure drop of conical spiral tube bundle are proposed both in laminar and turbulent fluid flow.On the based of the field synergy principle,the synergy of four vectors,the velocity,the velocity gradient,the temperature gradient and the pressure gradient,are calculated and discussed via the user defined function（UDF） program.The synergy angles β and θ,which respectively denote the performance of heat transfer enhancement and pressure drop of the conical spiral tube bundle,are analyzed.Finally,the comprehensive performance of the conical spiral tube is evaluated by the synergy angle γ and all of the three synergy angles of conical spiral tube bundle are compared to both bare tube and thin cylinder-interpolated tube.The analysis of the synergy angles shows that the heat transfer enhancement and pressure drop of conical spiral tube bundle are smaller than that of the thin cylinder-interpolated tube,while the comprehensive performance of conical spiral tube bundle is greater.The analysis of the heat transfer and pressure drop of conical spiral tube is valuable and instructional on the design and optimum of conical spiral tube bundle heat exchangers.

Synergistically Toughening Effect of SiC Whiskers and Nanoparticles in Al_2O_3-based Composite Ceramic Cutting Tool Material

In recent decades, many additives with different characteristics have been applied to strengthen and toughen Al2O3-based ceramic cutting tool materials. Among them, SiC whiskers and SiC nanoparticles showed excellent performance in improving the material properties. While no attempts have been made to add SiC whiskers and SiC nanoparticles together into the ceramic matrix and the synergistically toughening effects of them have not been studied. An Al2O3-SiCw-SiC np advanced ceramic cutting tool material is fabricated by adding both one-dimensional SiC whiskers and zero-dimensional SiC nanoparticles into the Al2O3 matrix with an effective dispersing and mixing process. The composites with 25 vol% SiC whiskers and 25 vol% SiC nanoparticles alone are also investegated for comparison purposes. Results show that the Al2O3-SiCw-SiCnp composite with both 20 vo1% SiC whiskers and 5 vol% SiC nanoparticles additives have much improved mechanical properties. The flexural strength of Al2O3-SiCw-SiCnp is 730＋ 95 MPa and fracture toughness is 5.6 ± 0.6 MPa.m1/2. The toughening and strengthening mechanisms of SiC whiskers and nanoparticles are studied when they are added either individually or in combination. It is indicated that when SiC whiskers and nanoparticles are added together, the grains are further refined and homogenized, so that the microstructure and fracture mode ratio is modified. The SiC nanoparticles are found helpful to enhance the toughening effects of the SiC whiskers. The proposed research helps to enrich the types of ceramic cutting tool and is benefit to expand the application range of ceramic cutting tool.

Mechanical Properties of Mo Fiber-reinforced Resin Mineral Composites with Different Mass Ratio of Resin and Hardener

Mo fibers were added to RMC with different mass ratios of resin and hardener to improve its mechanical properties. The influences of fiber surface state and hardener content on interface bonding strength and mechanical properties of RMC were studied, respectively. Furthermore, strain values of typical measuring points on samples of Mo fiber reinforced RMC(MFRRMC) under different loads were obtained by experiments and finite element analysis. The experimental results prove that scrap Mo fibers can improve interface bonding strength and mechanical properties of RMC better than new smooth Mo fibers because of the discharge pits randomly distributed on the surface of scrap fibers. With the decrease of hardener content, not only interface bonding strength between fiber and matrix, but also compression and flexural strength of MFRRMC increase firstly and then decrease. The properties are best while the mass ratio of resin and hardener reaches 4:1. It is indicated that finite element calculation data basically agree with experimental data by comparison of strain values on typical measuring points, which can provide an important intuitive reference for successive study on other mechanical properties of MFRRMC, validating the correctness of simulation method as well.

Multiscale design and biomechanical evaluation of porous spinal fusion cage to realize specified mechanical properties

Backgrou nd Dense titanium(Ti)fusion cages have been commonly used in transforaminal lumbar interbody fusion.However,the stiffness mismatch between cages and adjacent bone endplates increases the risk of stress shielding and cage subsidence.Methods The current study presents a multiscale optimization approach for porous Ti fusion cage development,including microscale topology optimization based on homogenization theory that obtains a unit cell with prescribed mechanical properties,and macroscale topology optimization that determines the layout of framework structure over the porous cage while maintaining the desired stiffness.The biomechanical performance of the designed porous cage is assessed using numerical simulations of fusion surgery.Selective laser melting is employed to assists with fabricating the designed porous structure and porous cage.Results The simulations demonstrate that the designed porous cage increases the strain energy density of bone grafts and decreases the peak stress on bone endplates.The mechanical and morphological discrepancies between the as-designed and fabricated porous structures are also described.Conclusion From the perspective of biomechanics,it is demonstrated that the designed porous cage contributes to reducing the risk of stress shielding and cage subsidence.The optimization of processing parameters and post-treatments are required to fabricate the designed porous cage.The present multiscale optimization approach can be extended to the development of cages with other shapes or materials and further types of orthopedic implants.

Vibration Response and Stress Analysis of Planar Elastic Tube Bundle Induced by Fluid Flow

Flow?induced vibration plays a positive role on heat transfer enhancement. Meanwhile, it is also a negative factor for fatigue strength. Satisfying the fatigue strength is the primary prerequisite for heat transfer enhancement. This paper numerically studied the flow?induced vibration of planar elastic tube bundle based on a two?way fluid–structure interaction(FSI) calculation. The numerical calculation involved the unsteady, three?dimensional incompressible governing equations solved with finite volume approach and the dynamic balance equation of planar elastic tube bundle solved with finite element method combined with dynamic mesh scheme. The numerical approach was verified by comparing with the published experimental results. Then the vibration trajectory, deformation and stress contour of planar elastic tube bundle were all studied. Results show that the combined movement of planar elastic tube bundle represents the agitation from inside to outside. The vibration of out?of?plane is the main vibration form with the typically sinusoidal behavior because the magnitude of displacement along the out?of?plane direction is the 100 times than the value of in?plane direction. The dangerous point locates in the innermost tube where the equivalent stress can be utilized to study the multiaxial fatigue of planar elastic tube bundle due to the alternating stress concentration. In the velocity range of 0.2-3 m/s, it is inferred that the vibration amplitude plays a role on the stress response and the stress amplitude is susceptible to the fluid velocity. This research paves a way for studying the fatigue strength of planar elastic tube bundle by flow?induced vibration.

Three‑dimensional Modeling and Simulation of Muscle Tissue Puncture Process

Needle biopsy is an essential part of modern clinical medicine.The puncture accuracy and sampling success rate of puncture surgery can be effectively improved through virtual surgery.There are few three-dimensional puncture(3D)models,which have little significance for surgical guidance under complicated conditions and restrict the development of virtual surgery.In this paper,a 3D simulation of the muscle tissue puncture process is studied.Firstly,the mechanical properties of muscle tissue are measured.The Mooney-Rivlin(M-R)model is selected by considering the fitting accuracy and calculation speed.Subsequently,an accurate 3D dynamic puncture model is established.The failure criterion is used to define the breaking characteristics of the muscle,and the bilinear cohesion model defines the breaking process.Experiments with different puncture speeds are carried out through the built in vitro puncture platform.The experimental results are compared with the simulation results.The experimental and simulated reaction force curves are highly consistent,which verifies the accuracy of the model.Finally,the model under different parameters is studied.The simulation results of varying puncture depths and puncture speeds are analyzed.The 3D puncture model can provide more accurate model support for virtual surgery and help improve the success rate of puncture surgery.

Introduction to the Special Issue on Novel Methods of Topology Optimization and Engineering Applications

Topology optimization,aiming to allocate the available material to maximize system performance while satisfying multiple constraints,has experienced tremendous progress.This special issue focuses on the new progress of topology optimization methods and their applications,especially theoretical development,numerical implementation and potential applications.

Effects of metal binder on the microstructure and mechanical properties of Al2O3-based micro-nanocomposite ceramic tool material

The Al_2O_3-（W,Ti）C composites with Ni and Mo additions varying from 0vol% to 12vol% were prepared via hot pressing sintering under 30 MPa. The microstructure was investigated via X-ray diffraction（XRD） and scanning electron microscopy（SEM） equipped with energy dispersive spectrometry（EDS）. Mechanical properties such as flexural strength, fracture toughness, and Vickers hardness were also measured. Results show that the main phases A12O3 and（W,Ti）C were detected by XRD. Compound Mo Ni also existed in sintered nanocomposites. The fracture modes of the nanocomposites were both intergranular and transgranular fractures. The plastic deformation of metal particles and crack bridging were the main toughening mechanisms. The maximum flexural strength and fracture toughness were obtained for 9vol% and 12vol% additions of Ni and Mo, respectively. The hardness of the composites reduced gradually with increasing content of metals Ni and Mo.

Progress in densification and toughening of high entropy carbide ceramics

High entropy carbide ceramics(HECC)are solid solution of inorganic compounds with five or more prin-cipal metal cations.Research interests in HECC are dramatically sparked by the enormous possibilities in composition-microstructure-property tailoring.As widely acknowledged,HECCs enjoy higher hardness and oxidation/corrosion/wear resistance,as well as lower thermal conductivity than conventional engi-neering carbide ceramics,making them the most potential candidates for state-of-the-art structural and functional applications in extreme service conditions.Despite the advantages,however,the poor den-sification coupled with low fracture toughness significantly limited the practical applications of HECC.Adding to the difficulty,the literature available for toughening HECC is woefully limited.In considera-tion of this insufficiency,we apply towards offer a comprehensive,critical review of the mechanical be-havior of HECC,highlighting the densification enhancing strategies(carbon content,sintering techniques,grain size,sintering aids,etc.)as well as toughening methods including particle toughening,whisker/fiber toughening,synergistic toughening,graphene-carbon nanotube toughening,to further the service reliabil-ity of HECC in practical industrial applications.Furthermore,despite some significant successes,important directions for further development of HECC are given as multi-dimensional gradient HECC,additive man-ufacturing of HECC,processing-composition-microstructure-property relationship prediction and genomes of HECC based on machine learning,and high-throughput computing,etc.

Microstructure refinement and work hardening in a machined surface layer induced by turning Inconel 718 super alloy

The microstructural changes in the machined surface layer of Ni-based super alloys essentially determine the final performance of the structural components of aerospace engines in which these alloys are used.In this work,multiscale metallurgical observations using scanning electron microscopy,electron-backscatter diffraction microscopy,and transmission electron microscopy were conducted to quantitatively characterize the microstructure of the machined subsurface.Next,to elucidate the factors that affect the formation of the refinement microstructure,the distributions of the deformation parameters(strain,strain rate,and temperature) in the machined subsurface were analyzed.A dislocation–twin interaction dynamic recrystallization mechanism for grain refinement during machining of Inconel 718 is proposed.Furthermore,microhardness evolution induced by grain refinement in the machined surface is evaluated.The results suggest that the gradient microstructure and the work hardening can be optimized by controlling the cutting parameters during turning of Inconel 718.

Reinforcing effect of graphene on the mechanical properties of Al2O3/TiC ceramics

Multilayer graphene(MLG)-reinforced Al_2O_3/TiC ceramics were fabricated through hot pressing sintering, and the reinforcing effect of MLG on the microstructure and mechanical properties of the composites was investigated by experiment and simulation. The simulation of dynamic crack initiation and propagation was investigated based on the cohesive zone method. The results show that the composite added with 0.2 wt% MLG has excellent flexural strength and high fracture toughness. The major reinforcing mechanisms are the synergistic effect by strong and weak bonding interfaces, MLG pull-out, and grain refinement resulting from the addition of MLG. In addition, the aggravating of crack deflection, branching, blunting, and bridging have indispensable contribution to the improvement of the as-designed materials.

A Review on Binderless Tungsten Carbide: Development and Application

WC-Co alloys have enjoyed great practical significance owing to their excellent properties during the past decades.Despite the advantages,however,recently there have been concerns about the challenges associated with the use of Co,i.e.price instability,toxicity and properties degeneration,which necessitates the fabrication of binderless tungsten carbide(BTC).On the other hand,BTC or BTC composites,none of them,to date has been commercialized and produced on an industrial scale,but only used to a limited extent for specialized applications,such as mechanical seals undergoing high burthen as well as high temperature electrical contacts.There are two challenges in developing BTC:fully densifying the sintered body together with achieving a high toughness.Thus,this review applies towards comprehensively summarize the current knowledge of sintering behavior,microstructure,and mechanical properties of BTC,highlighting the densification improving strategies as well as toughening methods,so as to provide reference for those who would like to enhance the performance of BTC with better reliability advancing them to further wide applications and prepare the material in a way that is environment friendly,harmless to human health and low in production cost.This paper shows that the fabrication of highly dense and high-performance BTC is economically and technically feasible.The properties of BTC can be tailored by judiciously selecting the chemical composition coupled with taking into careful account the effects of processing techniques and parameters.

Micro-milling of Pyramid Structured Surface for Implant Application

Surface modification,as a promising approach to improve biocompatibility of biomaterials,has captured extensive close attention among many researchers.Here,micro-milling technology was used in constructing pyramid micro-structures on the surface of Ti-6Al-4Vimplant.Cutting parameters,including spindle speed,feed rate and depth of cut,were optimized to control the generation of burrs.In addition,low melting point alloy was selected to extend the boundary of the workpiece as supporting material to prevent the generation of top burrs.The surface topographies were characterized using scanning electron microscope and laser scanning microscope.Results showed that the dimension of burrs decreased with the decrease of depth of cut,and the size of burrs decreased with the increase of feed rate.Moreover,burrs nearly not appeared on both sides of the micro-grooves machined with low melting point alloy(LMPA)coating.Pyramid micro-structure on the workpiece surface was built successfully by combining optimized cutting parameters(S=35kr/min,Vf=60mm/min,ap=5μm)and LMPA coating.

Characterization on the hydrodynamics of a covering-plate Rushton impeller

A modified Rushton impeller with two circular covering-plates mounted on the upper and lower sides of the blades was designed.There are gaps between the plates and the blades.The turbulent hydrodynamics was analyzed by the computational fluid dynamics(CFD) method.Firstly,the reliability of the numerical model and simulation method was verified by comparing with the experimental results from literature.Subsequently,the power consumption,flow pattern,mean velocity and mixing time of the covering-plate Rushton impeller(RT-C) were studied and compared with the standard Rushton impeller(RT) operated under the same conditions.Results show that the power consumption can be decreased about 18%.Compared with the almost unchanged flow field in the lower stirred tank,the mean velocity was increased at the upper half of the stirred tank.And in the impeller region,the mean axial and radial velocities were increased,the mean tangential velocity was decreased.In addition,the average mixing time of RT-C was shortened about 4.14% than the counterpart of RT.The conclusions obtained here indicated that RT-C has a more effective mixing performance and it can be used as an alternative of RT in the process industries.

Machinability of Hastelloy C-276 Using Hot-pressed Sintered Ti(C_7N_3)-based Cermet Cutting Tools

C-276 nickel-based alloy is a difficult-to-cut material. In high-speed machining of Hastelloy C-276, notching is a prominent failure mode due to high mechanical properties of work piece, which results in the short tool life and low productivity. In this paper, a newly developed Ti（C7N3）-based cermet insert manufactured by a hot-pressing method is used to machine the C-276 nickel-based alloy, and its cutting performances are studied. Based on orthogonal experiment method, the influence of cutting parameters on tool life, material removal rates and surface roughness are investigated. Experimental research results indicate that the optimal cutting condition is a cutting speed of 50 m/min, depth of cut of 0.4 mm and feed rate of 0.15 mm/r if the tool life and material removal rates are considered comprehensively. In this case, the tool life is 32 min and material removal rates are 3000 mm^3/min, which is appropriate to the rough machining. If the tool life and surface roughness are considered, the better cutting condition is a cutting speed of 75 m/min, depth of cut of 0.6 mm and feed rate of 0.1 mm/r. In this case, the surface roughness is 0.59μm. Notch wear, flank wear, chipping at the tool nose, built-up edge（BUE） and micro-cracks are found when Ti（C7N3）-based cermet insert turned Hastelloy C-276. Oxidation, adhesive, abrasive and diffusion are the wear mechanisms, which can be investigated by the observations of scanning electron microscope and energy-dispersive spectroscopy. This research will help to guide studies on the evaluation of machining parameters to further advance the productivity of nickel based alloy Hastelloy C-276 machining.