Intelligent manufacturing(IM),a driving force behind the fourth industrial revolution,is reshaping the manufacturing sector by enhancing productivity,efficiency,and sustainability.Despite the rapid technological advan...Intelligent manufacturing(IM),a driving force behind the fourth industrial revolution,is reshaping the manufacturing sector by enhancing productivity,efficiency,and sustainability.Despite the rapid technological advancements in IM,comprehensive bibliometric reviews remain limited.This article systematically reviews the latest research in IM,addressing emerging hotspots,key technologies,and their applications across the entire product manufacturing cycle.Bibliometric analysis is employed to identify research trends visualize publication volume,collaboration patterns,research domains,co-citations,and emerging areas of interest.The article then examines key technologies supporting IM,including sensors,the Internet of Things(IoT),big data analytics,cloud computing,artificial intelligence(AI),digital twins,and virtual reality(VR)/augmented reality(AR).Furthermore,it explores the application of these technologies throughout the manufacturing cycle-from intelligent reliability design,material transportation and tracking,to intelligent planning and scheduling,machining and fabrication,monitoring and maintenance,quality inspection and control,warehousing and management,and sustainable green manufacturing—through specific case studies.Lastly,the article discusses future research directions,highlighting the increasing global market and the need for enhanced interdisciplinary collaboration,technological integration,computing power upgrades,and attention to security and privacy in IM.This study provides valuable insights for scholars and serves as a guide for future research and strategic investment decisions,offering a comprehensive view of the IM field.展开更多
The use of Minimum Quantity Lubrication(MQL)with bio-lubricants has been extensively studied in aerospace sustainable manufacturing.Enhanced MQL technologies have been proposed to reduce tool wear and improve workpiec...The use of Minimum Quantity Lubrication(MQL)with bio-lubricants has been extensively studied in aerospace sustainable manufacturing.Enhanced MQL technologies have been proposed to reduce tool wear and improve workpiece surface integrity by increasing lubricant activity.However,the relationship between enhancement behavior,physicochemical properties of biolubricants,and processability remains unclear,presenting challenges for MQL technologies,particularly with difficult-to-machine materials.To address this gap,this paper provides an in-depth mechanism analysis and a comprehensive quantitative evaluation of the machinability of enhanced MQL technologies,considering chemistry,molecular dynamics,fluid dynamics,tribology,and heat transfer.Firstly,the cooling and lubrication enhancement mechanisms of nano-lubricants were systematically summarized.focusing on molecular structure.physical properties,and preparation processes.Secondly,the atomization enhancement mechanism of Electrostatic Minimum Quantity Lubrication(EMQL)was analyzed.revealing a 49%reduction in PM2.5 concentration during the atomization process compared to conventional MQL.Thirdly,the transport and infiltration enhancement mechanisms of bio-lubricants in cutting and grinding zones were summarized,incorporating electromagnetic fields and ultrasound-assisted processes.Finally,for cutting and grinding applications involving difficult-to-machine materials in aerospace,the optimized machinability of enhanced MQL technologies was concluded,showing a 50.1%increase in lubricant heat transfer coefficient and a 31.6%decrease in grinding temperature compared to standard MQL.This paper aims to help scientists understand the effective mechanisms,formulate process specifications,and identify future development trends in this technology.展开更多
As the manufacturing industry shifts toward environmentally sustainable practices,grinding—a high-precision pro-cessing method—is commonly used to ensure final workpiece dimensions and surface quality.The greening o...As the manufacturing industry shifts toward environmentally sustainable practices,grinding—a high-precision pro-cessing method—is commonly used to ensure final workpiece dimensions and surface quality.The greening of grind-ing processes has emerged as an important challenge for both academia and industry.Numerous studies proposing different methods for sustainable grinding have increased rapidly;however,the technical mechanisms and develop-ment trends remain unclear.This paper applies bibliometric methods to analyze relevant articles published on WOS from 2008 to 2023.Results show that China has the highest number of publications(45.38%),with research institu-tions primarily located in China,India,and Brazil.Among publishing journals,70%are classified as Q2 or above.Addi-tionally,popular authors and influential articles in this field are identified.Keyword frequency and hotspot literature analysis reveal that research focuses primarily on minimal quantity lubrication(MQL)grinding,especially using biolubricants and nanoparticles to improve grinding performance.This article reviews the mechanisms and effects of biolubricants and nanoparticles in MQL.It further examines how multi-energy field applications enhance MQL by influencing droplet atomization,wettability,and machining performance.A low-temperature field improves the heat exchange capacity of MQL droplets,while an electrostatic field enhances droplet contact angles and disper-sion.Ultrasonic energy enhances the atomization of biolubricants,and magnetic fields facilitate nanoparticle penetra-tion into the grinding zone,reducing grinding forces.Additionally,innovations in grinding wheel structures and solid lubrication grinding can reduce grinding temperatures and forces.This paper presents a comprehensive review of eco-friendly grinding development hotspots,providing technical support and theoretical guidance for academia and industry.展开更多
Microgrinding is widely used in clinical bone surgery,but saline spray cooling faces technical challenges such as low wettability at the microgrinding tool–bone interface,easy clogging of the microgrinding tools,and ...Microgrinding is widely used in clinical bone surgery,but saline spray cooling faces technical challenges such as low wettability at the microgrinding tool–bone interface,easy clogging of the microgrinding tools,and high grinding temperatures.These issues can lead to bone necrosis,irreversible thermal damage to nerves,or even surgical failure.Inspired by the water-trapping and directional transportation abilities of desert beetles,this study proposes a biomimetic desert beetle microgrinding tool.The flow-field distribution directly influences the convective heat transfer of the cooling medium in the grinding zone,which in turn affects the grinding temperature.To address this,a mathematical model of the two-phase flow field at the biomimetic microgrinding tool–bone interface is developed.The results indicate an average error of 14.74%between the calculated and experimentally obtained airflow field velocities.Next,a biomimetic desert beetle microgrinding tool is prepared.Experiments with physiological saline spray cooling were conducted on fresh bovine femur bone,which has mechanical properties similar to human bone.Results show that,compared with conventional microgrinding tools,the biomimetic tools reduced bone surface temperature by 21.7%,13.2%,5.8%,20.3%,and 25.8%at particle sizes of 150#,200#,240#,270#,and 300#,respectively.The surface morphology of the biomimetic microgrinding tools after grinding is observed and analyzed,revealing a maximum clogging area reduction of 23.0%,which is 6.1%,6.0%,10.0%,15.6%,and 9.5%less than that observed with conventional tools.Finally,this study unveils the dynamic mechanism of cooling medium transfer in the flow field at the biomimetic microgrinding tool–bone interface.This research provides theoretical guidance and technical support for clinical bone resection surgery.展开更多
In nanofluid minimum quantity lubrication(NMQL)milling of aviation aluminum alloy,it is the bottleneck problem to adjust the position parameters(target distance,incidence angle,and elevation angle)of the nozzle to imp...In nanofluid minimum quantity lubrication(NMQL)milling of aviation aluminum alloy,it is the bottleneck problem to adjust the position parameters(target distance,incidence angle,and elevation angle)of the nozzle to improve the surface roughness of milling,which has large and uncontrollable errors.In this paper,the influence law of milling cutter speed,helical angle,and cavity shape on the flow field around the milling cutter was studied,and the optimal nozzle profile parameters were obtained.Using 7050 aluminum alloy as the workpiece material,the milling experiment of the NMQL cavity was conducted by utilizing cottonseed oil-based Al2 O3 nanofluid.Results show that the high velocity of the surrounding air flow field and the strong gas barrier could be attributed to high rotating velocities of the milling cutter.The incidence angle of the nozzle was consistent with the helical angle of the milling cutter,the target distance was appropriate at 25–30 mm,and the elevation angle was suitable at 60°–65°.The range and variance analyses of the signal-to-noise ratio of milling force and roughness were performed,and the chip morphology was observed and analyzed.The results show that the optimal combination of nozzle position parameters was the target distance of 30 mm,the incidence angle of 35°,and the elevation angle of 60°.Among these parameters,target distance had the largest impact on cutting performance with a contribution rate of more than 55%,followed by incidence angle and elevation contribution rate.Analysis by orthogonal experiment revealed that the nozzle position parameters were appropriate,and Ra(0.087 lm)was reduced by 30.4%from the maximum value(0.125 lm).Moreover,Rsm(0.05 mm)was minimum,which was 36%lower than that of the seventh group(Rsm=0.078 mm).展开更多
Aluminum alloy is the main structural material of aircraft,launch vehicle,spaceship,and space station and is processed by milling.However,tool wear and vibration are the bottlenecks in the milling process of aviation ...Aluminum alloy is the main structural material of aircraft,launch vehicle,spaceship,and space station and is processed by milling.However,tool wear and vibration are the bottlenecks in the milling process of aviation aluminum alloy.The machining accuracy and surface quality of aluminum alloy milling depend on the cutting parameters,material mechanical properties,machine tools,and other parameters.In particular,milling force is the crucial factor to determine material removal and workpiece surface integrity.However,establishing the prediction model of milling force is important and difficult because milling force is the result of multiparameter coupling of process system.The research progress of cutting force model is reviewed from three modeling methods:empirical model,finite element simulation,and instantaneous milling force model.The problems of cutting force modeling are also determined.In view of these problems,the future work direction is proposed in the following four aspects:(1)high-speed milling is adopted for the thin-walled structure of large aviation with large cutting depth,which easily produces high residual stress.The residual stress should be analyzed under this particular condition.(2)Multiple factors(e.g.,eccentric swing milling parameters,lubrication conditions,tools,tool and workpiece deformation,and size effect)should be considered comprehensively when modeling instantaneous milling forces,especially for micro milling and complex surface machining.(3)The database of milling force model,including the corresponding workpiece materials,working condition,cutting tools(geometric figures and coatings),and other parameters,should be established.(4)The effect of chatter on the prediction accuracy of milling force cannot be ignored in thin-walled workpiece milling.(5)The cutting force of aviation aluminum alloy milling under the condition of minimum quantity lubrication(mql)and nanofluid mql should be predicted.展开更多
It is an inevitable trend of sustainable manufacturing to replace flood and dry machining with minimum quantity lubrication(MQL)technology.Nevertheless,for aeronautical difficult-tomachine materials,MQL couldn’t meet...It is an inevitable trend of sustainable manufacturing to replace flood and dry machining with minimum quantity lubrication(MQL)technology.Nevertheless,for aeronautical difficult-tomachine materials,MQL couldn’t meet the high demand of cooling and lubrication due to high heat generation during machining.Nano-biolubricants,especially non-toxic carbon group nano-enhancers(CGNs)are used,can solve this technical bottleneck.However,the machining mechanisms under lubrication of CGNs are unclear at complex interface between tool and workpiece,which characterized by high temperature,pressure,and speed,limited its application in factories and necessitates in-depth understanding.To fill this gap,this study concentrates on the comprehensive quantitative assessment of tribological characteristics based on force,tool wear,chip,and surface integrity in titanium alloy and nickel alloy machining and attempts to answer mechanisms systematically.First,to establish evaluation standard,the cutting mechanisms and performance improvement behavior covering antifriction,antiwear,tool failure,material removal,and surface formation of MQL were revealed.Second,the unique film formation and lubrication behaviors of CGNs in MQL turning,milling,and grinding are concluded.The influence law of molecular structure and micromorphology of CGNs was also answered and optimized options were recommended by considering diverse boundary conditions.Finally,in view of CGNs limitations in MQL,the future development direction is proposed,which needs to be improved in thermal stability of lubricant,activity of CGNs,controllable atomization and transportation methods,and intelligent formation of processing technology solutions.展开更多
Cutting fluid is crucial in ensuring surface quality and machining accuracy during machining.However,traditional mineral oil-based cutting fluids no longer meet modern machining’s health and environmental protection ...Cutting fluid is crucial in ensuring surface quality and machining accuracy during machining.However,traditional mineral oil-based cutting fluids no longer meet modern machining’s health and environmental protection require-ments.As a renewable,pollution-free alternative with excellent processing characteristics,vegetable oil has become an inevitable replacement.However,vegetable oil lacks oxidation stability,extreme pressure,and antiwear proper-ties,which are essential for machining requirements.The physicochemical characteristics of vegetable oils and the improved methods’application mechanism are not fully understood.This study aims to investigate the effects of viscosity,surface tension,and molecular structure of vegetable oil on cooling and lubricating properties.The mechanisms of autoxidation and high-temperature oxidation based on the molecular structure of vegetable oil are also discussed.The study further investigates the application mechanism and performance of chemical modification and antioxidant additives.The study shows that the propionic ester of methyl hydroxy-oleate obtained by epoxidation has an initial oxidation temperature of 175℃.The application mechanism and extreme pressure performance of conventional extreme pressure additives and nanoparticle additives were also investigated to solve the problem of insufficient oxidation resistance and extreme pressure performance of nanobiological lubricants.Finally,the study discusses the future prospects of vegetable oil for chemical modification and nanoparticle addition.The study provides theoretical guidance and technical support for the industrial application and scientific research of vegetable oil in the field of lubrication and cooling.It is expected to promote sustainable development in the manufacturing industry.展开更多
The application of cutting fluid in the field of engineering manufacturing has a history of hundreds of years,and it plays a vital role in the processing efficiency and surface quality of parts.Among them,water-based ...The application of cutting fluid in the field of engineering manufacturing has a history of hundreds of years,and it plays a vital role in the processing efficiency and surface quality of parts.Among them,water-based cutting fluid accounts for more than 90%of the consumption of cutting fluid.However,long-term recycling of water-based cutting fluid could easily cause deterioration,and the breeding of bacteria could cause the cutting fluid to fail,increase manufacturing costs,and even endanger the health of workers.Traditional bactericides could improve the biological stability of cutting fluids,but they are toxic to the environment and do not conform to the development trend of low-carbon manufacturing.Low-carbon manufacturing is inevitable and the direction of sustainable manufacturing.The use of nanomaterials,transition metal complexes,and physical sterilization methods on the bacterial cell membrane and genetic material could effectively solve this problem.In this article,the mechanism of action of additives and microbial metabolites was first analyzed.Then,the denaturation mechanism of traditional bactericides on the target protein and the effect of sterilization efficiency were summarized.Further,the mechanism of nanomaterials disrupting cell membrane potential was discussed.The effects of lipophilicity and the atomic number of transition metal complexes on cell membrane penetration were also summarized,and the effects of ultraviolet rays and ozone on the destruction of bacterial genetic material were reviewed.In other words,the bactericidal performance,hazard,degradability,and economics of various sterilization methods were comprehensively evaluated,and the potential development direction of improving the biological stability of cutting fluid was proposed.展开更多
Metal cutting fluids(MCFs)under flood conditions do not meet the urgent needs of reducing carbon emission.Biolubricant-based minimum quantity lubrication(MQL)is an effective alternative to flood lubrication.However,pn...Metal cutting fluids(MCFs)under flood conditions do not meet the urgent needs of reducing carbon emission.Biolubricant-based minimum quantity lubrication(MQL)is an effective alternative to flood lubrication.However,pneumatic atomization MQL has poor atomization properties,which is detrimental to occupational health.Therefore,electrostatic atomization MQL requires preliminary exploratory studies.However,systematic reviews are lacking in terms of capturing the current research status and development direction of this technology.This study aims to provide a comprehensive review and critical assessment of the existing understanding of electrostatic atomization MQL.This research can be used by scientists to gain insights into the action mechanism,theoretical basis,machining performance,and development direction of this technology.First,the critical equipment,eco-friendly atomization media(biolubricants),and empowering mechanisms of electrostatic atomization MQL are presented.Second,the advanced lubrication and heat transfer mechanisms of biolubricants are revealed by quantitatively comparing MQL with MCF-based wet machining.Third,the distinctive wetting and infiltration mechanisms of electrostatic atomization MQL,combined with its unique empowering mechanism and atomization method,are compared with those of pneumatic atomization MQL.Previous experiments have shown that electrostatic atomization MQL can reduce tool wear by 42.4%in metal cutting and improve the machined surface Ra by 47%compared with pneumatic atomization MQL.Finally,future development directions,including the improvement of the coordination parameters and equipment integration aspects,are proposed.展开更多
Nanofluid minimum quantity lubrication(NMQL)is a green processing technology.Cottonseed oil is suitable as base oil because of excellent lubrication performance,low freezing temperature,and high yield.Al_(2)O_(3)nanop...Nanofluid minimum quantity lubrication(NMQL)is a green processing technology.Cottonseed oil is suitable as base oil because of excellent lubrication performance,low freezing temperature,and high yield.Al_(2)O_(3)nanoparticles improve not only the heat transfer capacity but also the lubrication performance.The physical and chemical proper-ties of nanofluid change when Al_(2)O_(3)nanoparticles are added.However,the effects of the concentration of nanofluid on lubrication performance remain unknown.Furthermore,the mechanisms of interaction between Al_(2)O_(3)nanoparti-cles and cottonseed oil are unclear.In this research,nanofluid is prepared by adding different mass concentrations of Al_(2)O_(3)nanoparticles(0,0.2%,0.5%,1%,1.5%,and 2%wt)to cottonseed oil during minimum quantity lubrication(MQL)milling 45 steel.The tribological properties of nanofluid with different concentrations at the tool/workpiece interface are studied through macro-evaluation parameters(milling force,specific energy)and micro-evaluation parameters(surface roughness,micro morphology,contact angle).The result show that the specific energy is at the minimum(114 J/mm^(3)),and the roughness value is the lowest(1.63μm)when the concentration is 0.5 wt%.The surfaces of the chip and workpiece are the smoothest,and the contact angle is the lowest,indicating that the tribological proper-ties are the best under 0.5 wt%.This research investigates the intercoupling mechanisms of Al_(2)O_(3)nanoparticles and cottonseed base oil,and acquires the optimal Al_(2)O_(3)nanofluid concentration to receive satisfactory tribological properties.展开更多
Micro-grinding with a spherical grinding head has been deemed an indispensable method in high-risk surgeries, such as neurosurgery and spine surgery, where bone grinding has long been plagued by the technical bottlene...Micro-grinding with a spherical grinding head has been deemed an indispensable method in high-risk surgeries, such as neurosurgery and spine surgery, where bone grinding has long been plagued by the technical bottleneck of mechanical stress-induced crack damage. In response to this challenge, the ultrasound-assisted biological bone micro-grinding novel process with a spherical grinding head has been proposed by researchers. Force modeling is a prerequisite for process parameter determination in orthopedic surgery, and the difculty in establishing and accurately predicting bone micro-grinding force prediction models is due to the geometric distribution of abrasive grains and the dynamic changes in geometry and kinematics during the cutting process. In addressing these critical needs and technical problems, the shape and protrusion heights of the wear particle of the spherical grinding head were frst studied, and the gradual rule of the contact arc length under the action of high-speed rotating ultrasonic vibration was proposed. Second, the mathematical model of the maximum thickness of undeformed chips under ultrasonic vibration of the spherical grinding head was established. Results showed that ultrasonic vibration can reduce the maximum thickness of undeformed chips and increase the range of ductile and bone meal removals, revealing the mechanism of reducing grinding force. Further, the dynamic grinding behavior of diferent layers of abrasive particles under diferent instantaneous interaction states was studied. Finally, a prediction model of micro-grinding force was established in accordance with the relationship between grinding force and cutting depth, revealing the mechanism of micro-grinding force transfer under ultrasonic vibration. The theoretical model’s average deviations are 10.37% in x-axis direction, 6.85% in y-axis direction, and 7.81% in z-axis direction compared with the experimental results. This study provides theoretical guidance and technical support for clinical bone micro-grinding.展开更多
Minimum quantity Lubrication(MQL)is a sustainable lubrication system that is famous in many machining systems.It involve the spray of an infinitesimal amount of mist-like lubricants during machining processes.The MQL ...Minimum quantity Lubrication(MQL)is a sustainable lubrication system that is famous in many machining systems.It involve the spray of an infinitesimal amount of mist-like lubricants during machining processes.The MQL system is affirmed to exhibit an excellent machining performance,and it is highly economical.The nanofluids are understood to exhibit excellent lubricity and heat evacuation capability,compared to pure oil-based MQL system.Studies have shown that the surface quality and amount of energy expended in the grinding operations can be reduced considerably due to the positive effect of these nanofluids.This work presents an experimental study on the tribological performance of SiO_(2)nanofluid during grinding of Si_(3)N_(4)ceramic.The effect different grinding modes and lubrication systems during the grinding operation was also analyzed.Different concentrations of the SiO_(2)nanofluid was manufactured using canola,corn and sunflower oils.The quantitative evaluation of the grinding process was done based on the amount of grinding forces,specific grinding energy,frictional coefficient,and surface integrity.It was found that the canola oil exhibits optimal lubrication performance compared to corn oil,sunflower oil,and traditional lubrication systems.Additionally,the introduction of ultrasonic vibrations with the SiO_(2)nanofluid in MQL system was found to reduce the specific grinding energy,normal grinding forces,tangential grinding forces,and surface roughness by 65%,57%,65%,and 18%respectively.Finally,regression analysis was used to obtain an optimum parameter combinations.The observations from this work will aid the smooth transition towards ecofriendly and sustainable machining of engineering ceramics.展开更多
Graphene has superhigh thermal conductivity up to 5000 W/(m·K),extremely thin thickness,superhigh mechanical strength and nano-lamellar structure with low interlayer shear strength,making it possess great potenti...Graphene has superhigh thermal conductivity up to 5000 W/(m·K),extremely thin thickness,superhigh mechanical strength and nano-lamellar structure with low interlayer shear strength,making it possess great potential in mini-mum quantity lubrication(MQL)grinding.Meanwhile,ionic liquids(ILs)have higher thermal conductivity and better thermal stability than vegetable oils,which are frequently used as MQL grinding fluids.And ILs have extremely low vapor pressure,thereby avoiding film boiling in grinding.These excellent properties make ILs also have immense potential in MQL grinding.However,the grinding performance of graphene and ionic liquid mixed fluid under nano-fluid minimum quantity lubrication(NMQL),and its tribological mechanism on abrasive grain/workpiece grinding interface,are still unclear.This research firstly evaluates the grinding performance of graphene and ionic liquid mixed nanofluids(graphene/IL nanofluids)under NMQL experimentally.The evaluation shows that graphene/IL nanofluids can further strengthen both the cooling and lubricating performances compared with MQL grinding using ILs only.The specific grinding energy and grinding force ratio can be reduced by over 40%at grinding depth of 10μm.Work-piece machined surface roughness can be decreased by over 10%,and grinding temperature can be lowered over 50℃at grinding depth of 30μm.Aiming at the unclear tribological mechanism of graphene/IL nanofluids,molecular dynamics simulations for abrasive grain/workpiece grinding interface are performed to explore the formation mechanism of physical adsorption film.The simulations show that the grinding interface is in a boundary lubrication state.IL molecules absorb in groove-like fractures on grain wear flat face to form boundary lubrication film,and graphene nanosheets can enter into the grinding interface to further decrease the contact area between abrasive grain and workpiece.Compared with MQL grinding,the average tangential grinding force of graphene/IL nanofluids can decrease up to 10.8%.The interlayer shear effect and low interlayer shear strength of graphene nanosheets are the principal causes of enhanced lubricating performance on the grinding interface.EDS and XPS analyses are further carried out to explore the formation mechanism of chemical reaction film.The analyses show that IL base fluid happens chemical reactions with workpiece material,producing FeF_(2),CrF_(3),and BN.The fresh machined surface of workpiece is oxidized by air,producing NiO,Cr_(2)O_(3) and Fe_(2)O_(3).The chemical reaction film is constituted by fluorides,nitrides and oxides together.The combined action of physical adsorption film and chemical reaction film make graphene/IL nano-fluids obtain excellent grinding performance.展开更多
The machining surface integrity of aero-engine turbine disc slots has a significant impact on their fatigue life and service performance,and achieving efficiency and high-precision machining is still a great challenge...The machining surface integrity of aero-engine turbine disc slots has a significant impact on their fatigue life and service performance,and achieving efficiency and high-precision machining is still a great challenge.The high machining requirements of future aeroengine turbine disc slots will be difficult to satisfy using the broaching method.In addition,existing methods of slot machin-ing face difficulties in ensuring surface integrity.This study explored a cup shaped electroplated Cubic Boron Nitride(CBN)abrasive wheel for profile grinding the turbine disc slots of FGH96 powder metallurgy superalloy.The matrix structure of the cup shaped abrasive wheel was designed and verified.A profile grinding experiment was conducted for fir-tree slots on a five-axis machining center.The accuracy and the surface integrity were analyzed.Results show that the key dimension detection results of the slots were within the allowable tolerance range.Meanwhile,an average sur-face roughness Ra of 0.55μm was achieved,the residual stress was compressive,the plastic defor-mation layer thickness was less than 5μm,and the hardening layer thickness was less than 20μm.The research findings provide a new approach to machining the slots of aviation engine turbine discs and guidance for the high-quality processing of complex components.展开更多
The surface morphology and roughness of a workpiece are crucial parameters in grinding processes.Accurate prediction of these parameters is essential for maintaining the workpiece’s surface integrity.However,the rand...The surface morphology and roughness of a workpiece are crucial parameters in grinding processes.Accurate prediction of these parameters is essential for maintaining the workpiece’s surface integrity.However,the randomness of abrasive grain shapes and workpiece surface formation behaviors poses significant challenges,and accuracy in current physical mechanism-based predictive models is needed.To address this problem,by using the random plane method and accounting for the random morphology and distribution of abrasive grains,this paper proposes a novel method to model CBN grinding wheels and predict workpiece surface roughness.First,a kinematic model of a single abrasive grain is developed to accurately capture the three-dimensional morphology of the grinding wheel.Next,by formulating an elastic deformation and formation model of the workpiece surface based on Hertz theory,the variation in grinding arc length at different grinding depths is revealed.Subsequently,a predictive model for the surface morphology of the workpiece ground by a single abrasive grain is devised.This model integrates the normal distribution model of abrasive grain size and the spatial distribution model of abrasive grain positions,to elucidate how the circumferential and axial distribution of abrasive grains influences workpiece surface formation.Lastly,by integrating the dynamic effective abrasive grain model,a predictive model for the surface morphology and roughness of the grinding wheel is established.To examine the impact of changing the grit size of the grinding wheel and grinding depth on workpiece surface roughness,and to validate the accuracy of the model,experiments are conducted.Results indicate that the predicted three-dimensional morphology of the grinding wheel and workpiece surfaces closely matches the actual grinding wheel and ground workpiece surfaces,with surface roughness prediction deviations as small as 2.3%.展开更多
Pattern synthesise of antenna arrays is usually complicated optimization problems,while evolutionary algorithms(EAs)are promising in solving these problems.This paper does not propose a new EA,but does construct a new...Pattern synthesise of antenna arrays is usually complicated optimization problems,while evolutionary algorithms(EAs)are promising in solving these problems.This paper does not propose a new EA,but does construct a new form of optimization problems.The new optimization formulation has two differences from the common ones.One is the objective function is the field error between the desired and the designed,not the usual amplitude error between the desired and the designed.This difference is beneficial to decrease complexity in some sense.The second difference is that the design variables are changed as phases of desired radiation field within shaped-region,instead of excitation parameters.This difference leads to the reduction of the number of design variables.A series of synthesis experiments including equally and unequally spaced linear arrays with different pattern shape requirements are applied,and the effectiveness and advantages of the proposed new optimization problems are validated.The results show that the proposing a new optimization formulation with less complexity is as significant as proposing a new algorithm.展开更多
High-efficiency abrasive process with CBN grinding wheel is one of the important techniques of advanced manufacture. Combined with raw and finishing machining, it can attain high material removal rate like turning, mi...High-efficiency abrasive process with CBN grinding wheel is one of the important techniques of advanced manufacture. Combined with raw and finishing machining, it can attain high material removal rate like turning, milling and planning. The difficult-to-grinding materials can also be ground by means of this method with high performance. In the present paper, development status and latest progresses on high-efficiency abrasive machining technologies with CBN grinding wheel relate to high speed and super-high speed grinding, quick point-grinding, high efficiency deep-cut grinding, creep feed deep grinding, heavy-duty snagging and abrasive belt grinding were summarized. The efficiency and parameters range of these abrasive machining processes were compared. The key technologies of high efficiency abrasive machining, including grinding wheel, spindle and bearing, grinder, coolant supplying, installation and orientation of wheel and workpiece and safety defended, as well as intelligent monitor and NC grinding were investigated. It is concluded that high efficiency abrasive machining is a promising technology in the future.展开更多
During the metal cutting process,especially in continuous contact conditions like turning,the challenge of lubricants failing to effectively reach the cutting point remains unresolved.Micro-textured cutting tools offe...During the metal cutting process,especially in continuous contact conditions like turning,the challenge of lubricants failing to effectively reach the cutting point remains unresolved.Micro-textured cutting tools offer a potential solution for tool-chip contact challenges.Inspired by the evolutionary achievements of the biosphere,micro-textures are expected to overcome lubrication limitations in cutting zones.Drawing on the anti-gravity water transport seen at the mouth edge of the Nepenthes plant,an innovative microchannel with Nepenthes-shaped contours was designed on the rake face to enable controlled lubricant transport.However,the dynamics of lubricant delivery on textured surfaces are not fully understood.This study first analyzed the microstructure and water transport mechanism of Nepenthes to reconstruct a micro-textured surface for controlled lubricant transport.A dynamic model was then developed to describe lubricant transport within open microchannels,with mathematical simulations predicting transport speed and flow distance.To validate this model,diffusion experiments of alumina soybean oil nanolubricant on polycrystalline diamond(PCD)cutting tool surfaces were conducted,showing an average prediction deviation of 5.01%.Compared with the classical Lucas-Washburn model,the new model improved prediction accuracy by 4.72%.Additionally,comparisons were made to examine droplet spreading and non-uniform diffusion on textured surfaces,revealing that the T2 surface exhibited the strongest unidirectional diffusion characteristics.The contact angle ratio,droplet unidirectional spreading ratio,and droplet spreading aspect ratio were 0.48,1.75,and 3.99,respectively.Finally,the anti-wear,friction-reducing,and efficiency-enhancing mechanisms of micro-textured surfaces in minimum quantity lubrication turning were analyzed.This approach may support continuous cutting of difficult-tomachine materials.展开更多
Too high grinding force will lead to a large increase in specific grinding energy, resulting in high temperature in grinding zone, especially for the aerospace difficult cutting metal materials,seriously affecting the...Too high grinding force will lead to a large increase in specific grinding energy, resulting in high temperature in grinding zone, especially for the aerospace difficult cutting metal materials,seriously affecting the surface quality and accuracy. At present, the theoretical models of grinding force are mostly based on the assumption of uniform or simplified morphological characteristics of grains, which is inconsistent with the actual grains. Especially for non-engineering grinding wheel,most geometric characteristics of grains are ignored, resulting in the calculation accuracy that cannot guide practical production. Based on this, an improved grinding force model based on random grain geometric characteristics is proposed in this paper. Firstly, the surface topography model of CBN grinding wheel is established, and the effective grain determination mechanism in grinding zone is revealed. Based on the known grinding force model and mechanical behavior of interaction between grains and workpiece in different stages, the concept of grain effective action area is proposed. The variation mechanism of effective action area under the influence of grain geometric and spatial characteristics is deeply analyzed, and the calculation method under random combination of five influencing parameters is obtained. The numerical simulation is carried out to reveal the dynamic variation process of grinding force in grinding zone. In order to verify the theoretical model, the experiments of dry grinding Ti-6Al-4 V are designed. The experimental results show that under different machining parameters, the results of numerical calculation and experimental measurement are in good agreement, and the minimum error value is only 2.1 %, which indicates that the calculation accuracy of grinding force model meets the requirements and is feasible. This study will provide a theoretical basis for optimizing the wheel structure, effectively controlling the grinding force range, adjusting the grinding zone temperature and improving the workpiece machining quality in the industrial grinding process.展开更多
基金Supported by National Natural Science Foundation of China(Grant Nos.52375447,52305477 and 52105457)the Shandong Provincial Natural Science Foundation of China(Grant Nos.ZR2023QE057,ZR2024QE100 and ZR2024ME255)+2 种基金Qingdao Municipal Science and Technology Planning Park Cultivation Plan(Grant No.23-1-5-yqpy-17-qy)Shandong Provincial Science and Technology SMEs Innovation Capacity Improvement Project(Grant No.2022TSGC1115)the Special Fund of Taishan Scholars Project。
文摘Intelligent manufacturing(IM),a driving force behind the fourth industrial revolution,is reshaping the manufacturing sector by enhancing productivity,efficiency,and sustainability.Despite the rapid technological advancements in IM,comprehensive bibliometric reviews remain limited.This article systematically reviews the latest research in IM,addressing emerging hotspots,key technologies,and their applications across the entire product manufacturing cycle.Bibliometric analysis is employed to identify research trends visualize publication volume,collaboration patterns,research domains,co-citations,and emerging areas of interest.The article then examines key technologies supporting IM,including sensors,the Internet of Things(IoT),big data analytics,cloud computing,artificial intelligence(AI),digital twins,and virtual reality(VR)/augmented reality(AR).Furthermore,it explores the application of these technologies throughout the manufacturing cycle-from intelligent reliability design,material transportation and tracking,to intelligent planning and scheduling,machining and fabrication,monitoring and maintenance,quality inspection and control,warehousing and management,and sustainable green manufacturing—through specific case studies.Lastly,the article discusses future research directions,highlighting the increasing global market and the need for enhanced interdisciplinary collaboration,technological integration,computing power upgrades,and attention to security and privacy in IM.This study provides valuable insights for scholars and serves as a guide for future research and strategic investment decisions,offering a comprehensive view of the IM field.
基金supported by the following organizations:the Special Fund of Taishan Scholars Project(No.tsqn202211179)the National Natural Science Foundation of China(No.52105457)+2 种基金Young Talent of Lifting engineering for Science and Technology in Shandong,China(No.SDAST2021qt12)the National Natural Science Foundation of China(No.52375447)China Postdoctoral Science Foundation Funded Project(No.2023M732826).
文摘The use of Minimum Quantity Lubrication(MQL)with bio-lubricants has been extensively studied in aerospace sustainable manufacturing.Enhanced MQL technologies have been proposed to reduce tool wear and improve workpiece surface integrity by increasing lubricant activity.However,the relationship between enhancement behavior,physicochemical properties of biolubricants,and processability remains unclear,presenting challenges for MQL technologies,particularly with difficult-to-machine materials.To address this gap,this paper provides an in-depth mechanism analysis and a comprehensive quantitative evaluation of the machinability of enhanced MQL technologies,considering chemistry,molecular dynamics,fluid dynamics,tribology,and heat transfer.Firstly,the cooling and lubrication enhancement mechanisms of nano-lubricants were systematically summarized.focusing on molecular structure.physical properties,and preparation processes.Secondly,the atomization enhancement mechanism of Electrostatic Minimum Quantity Lubrication(EMQL)was analyzed.revealing a 49%reduction in PM2.5 concentration during the atomization process compared to conventional MQL.Thirdly,the transport and infiltration enhancement mechanisms of bio-lubricants in cutting and grinding zones were summarized,incorporating electromagnetic fields and ultrasound-assisted processes.Finally,for cutting and grinding applications involving difficult-to-machine materials in aerospace,the optimized machinability of enhanced MQL technologies was concluded,showing a 50.1%increase in lubricant heat transfer coefficient and a 31.6%decrease in grinding temperature compared to standard MQL.This paper aims to help scientists understand the effective mechanisms,formulate process specifications,and identify future development trends in this technology.
基金Supported by National Natural Science Foundation of China(Grant Nos.52375447,52305477 and 52105457)Shandong Provincial Natural Science Foundation(Grant Nos.ZR2023QE057,ZR2024QE100 and ZR2024ME255)+2 种基金Qingdao Municipal Science and Technology Planning Park Cultivation Plan(Grant No.23-1-5-yqpy-17-qy)Shandong Provincial Science and Technology SMEs Innovation Capacity Improvement Project(Grant No.2022TSGC1115)the Special Fund of Taishan Scholars。
文摘As the manufacturing industry shifts toward environmentally sustainable practices,grinding—a high-precision pro-cessing method—is commonly used to ensure final workpiece dimensions and surface quality.The greening of grind-ing processes has emerged as an important challenge for both academia and industry.Numerous studies proposing different methods for sustainable grinding have increased rapidly;however,the technical mechanisms and develop-ment trends remain unclear.This paper applies bibliometric methods to analyze relevant articles published on WOS from 2008 to 2023.Results show that China has the highest number of publications(45.38%),with research institu-tions primarily located in China,India,and Brazil.Among publishing journals,70%are classified as Q2 or above.Addi-tionally,popular authors and influential articles in this field are identified.Keyword frequency and hotspot literature analysis reveal that research focuses primarily on minimal quantity lubrication(MQL)grinding,especially using biolubricants and nanoparticles to improve grinding performance.This article reviews the mechanisms and effects of biolubricants and nanoparticles in MQL.It further examines how multi-energy field applications enhance MQL by influencing droplet atomization,wettability,and machining performance.A low-temperature field improves the heat exchange capacity of MQL droplets,while an electrostatic field enhances droplet contact angles and disper-sion.Ultrasonic energy enhances the atomization of biolubricants,and magnetic fields facilitate nanoparticle penetra-tion into the grinding zone,reducing grinding forces.Additionally,innovations in grinding wheel structures and solid lubrication grinding can reduce grinding temperatures and forces.This paper presents a comprehensive review of eco-friendly grinding development hotspots,providing technical support and theoretical guidance for academia and industry.
基金Supported by National Natural Science Foundation of China(Grant Nos.52205481,52305477)Outstanding Youth Innovation Team in Universities of Shandong Province(Grant No.2023KJ114)+2 种基金Qingdao Science and Technology Planning Park Cultivation Plan(Grant No.23-1-5-yqpy-17-qy)Young Talent of Lifting engineering for Science and Technology in Shandong(Grant No.SDAST2024QTA043)Key Lab of Industrial Fluid Energy Conservation and Pollution Control(Ministry of Education)(Grant No.CK-2024-0033)。
文摘Microgrinding is widely used in clinical bone surgery,but saline spray cooling faces technical challenges such as low wettability at the microgrinding tool–bone interface,easy clogging of the microgrinding tools,and high grinding temperatures.These issues can lead to bone necrosis,irreversible thermal damage to nerves,or even surgical failure.Inspired by the water-trapping and directional transportation abilities of desert beetles,this study proposes a biomimetic desert beetle microgrinding tool.The flow-field distribution directly influences the convective heat transfer of the cooling medium in the grinding zone,which in turn affects the grinding temperature.To address this,a mathematical model of the two-phase flow field at the biomimetic microgrinding tool–bone interface is developed.The results indicate an average error of 14.74%between the calculated and experimentally obtained airflow field velocities.Next,a biomimetic desert beetle microgrinding tool is prepared.Experiments with physiological saline spray cooling were conducted on fresh bovine femur bone,which has mechanical properties similar to human bone.Results show that,compared with conventional microgrinding tools,the biomimetic tools reduced bone surface temperature by 21.7%,13.2%,5.8%,20.3%,and 25.8%at particle sizes of 150#,200#,240#,270#,and 300#,respectively.The surface morphology of the biomimetic microgrinding tools after grinding is observed and analyzed,revealing a maximum clogging area reduction of 23.0%,which is 6.1%,6.0%,10.0%,15.6%,and 9.5%less than that observed with conventional tools.Finally,this study unveils the dynamic mechanism of cooling medium transfer in the flow field at the biomimetic microgrinding tool–bone interface.This research provides theoretical guidance and technical support for clinical bone resection surgery.
基金the National Natural Science Foundation of China(Nos.51975305,51806112and 51905289)the Major Research Project of Shandong Province of China(Nos.2019GGX104040 and 2019GSF108236)+2 种基金the Shandong Provincial Natural Science Foundation of China(No.ZR2019PEE008)Major Science and Technology Innovation Engineering Projects of Shandong Province of China(No.2019JZZY020111)Applied Basic Research Youth Project of Qingdao Science and Technology Plan of China(No.19-6-2-63-cg)。
文摘In nanofluid minimum quantity lubrication(NMQL)milling of aviation aluminum alloy,it is the bottleneck problem to adjust the position parameters(target distance,incidence angle,and elevation angle)of the nozzle to improve the surface roughness of milling,which has large and uncontrollable errors.In this paper,the influence law of milling cutter speed,helical angle,and cavity shape on the flow field around the milling cutter was studied,and the optimal nozzle profile parameters were obtained.Using 7050 aluminum alloy as the workpiece material,the milling experiment of the NMQL cavity was conducted by utilizing cottonseed oil-based Al2 O3 nanofluid.Results show that the high velocity of the surrounding air flow field and the strong gas barrier could be attributed to high rotating velocities of the milling cutter.The incidence angle of the nozzle was consistent with the helical angle of the milling cutter,the target distance was appropriate at 25–30 mm,and the elevation angle was suitable at 60°–65°.The range and variance analyses of the signal-to-noise ratio of milling force and roughness were performed,and the chip morphology was observed and analyzed.The results show that the optimal combination of nozzle position parameters was the target distance of 30 mm,the incidence angle of 35°,and the elevation angle of 60°.Among these parameters,target distance had the largest impact on cutting performance with a contribution rate of more than 55%,followed by incidence angle and elevation contribution rate.Analysis by orthogonal experiment revealed that the nozzle position parameters were appropriate,and Ra(0.087 lm)was reduced by 30.4%from the maximum value(0.125 lm).Moreover,Rsm(0.05 mm)was minimum,which was 36%lower than that of the seventh group(Rsm=0.078 mm).
基金Suppo rted by National Natural Science Foundation of China(Grant Nos.51975305,51905289)Major Research Project of Shandong Province of China(Grant Nos.2019GGX104040,2019GSF108236)+2 种基金Major Science and Technology Innovation Engineering Projects of Shandong Province of China(Grant No.2019JZZY020111)the Natural Scie nce Foundation of Shandong Province(Grant Nos.ZR2020KE027 and ZR2020ME158)Applied Basic Research Youth Project of Qingdao Science and Technology Plan of China(Grant No.19-6-2-63-cg).
文摘Aluminum alloy is the main structural material of aircraft,launch vehicle,spaceship,and space station and is processed by milling.However,tool wear and vibration are the bottlenecks in the milling process of aviation aluminum alloy.The machining accuracy and surface quality of aluminum alloy milling depend on the cutting parameters,material mechanical properties,machine tools,and other parameters.In particular,milling force is the crucial factor to determine material removal and workpiece surface integrity.However,establishing the prediction model of milling force is important and difficult because milling force is the result of multiparameter coupling of process system.The research progress of cutting force model is reviewed from three modeling methods:empirical model,finite element simulation,and instantaneous milling force model.The problems of cutting force modeling are also determined.In view of these problems,the future work direction is proposed in the following four aspects:(1)high-speed milling is adopted for the thin-walled structure of large aviation with large cutting depth,which easily produces high residual stress.The residual stress should be analyzed under this particular condition.(2)Multiple factors(e.g.,eccentric swing milling parameters,lubrication conditions,tools,tool and workpiece deformation,and size effect)should be considered comprehensively when modeling instantaneous milling forces,especially for micro milling and complex surface machining.(3)The database of milling force model,including the corresponding workpiece materials,working condition,cutting tools(geometric figures and coatings),and other parameters,should be established.(4)The effect of chatter on the prediction accuracy of milling force cannot be ignored in thin-walled workpiece milling.(5)The cutting force of aviation aluminum alloy milling under the condition of minimum quantity lubrication(mql)and nanofluid mql should be predicted.
基金supported by the National Natural Science Foundation of China(Nos.51975305 and 51905289)the Major Research Project of Shandong Province(No.2019GGX104040)+2 种基金the Major Science and Technology Innovation Engineering Projects of Shandong Province(No.2019JZZY020111)the Natural Science Foundation of Shandong Province(Nos.ZR2020KE027 and ZR2020ME158)the Applied Basic Research Youth Project of Qingdao science and technology plan(No.19-6-2-63-cg)。
文摘It is an inevitable trend of sustainable manufacturing to replace flood and dry machining with minimum quantity lubrication(MQL)technology.Nevertheless,for aeronautical difficult-tomachine materials,MQL couldn’t meet the high demand of cooling and lubrication due to high heat generation during machining.Nano-biolubricants,especially non-toxic carbon group nano-enhancers(CGNs)are used,can solve this technical bottleneck.However,the machining mechanisms under lubrication of CGNs are unclear at complex interface between tool and workpiece,which characterized by high temperature,pressure,and speed,limited its application in factories and necessitates in-depth understanding.To fill this gap,this study concentrates on the comprehensive quantitative assessment of tribological characteristics based on force,tool wear,chip,and surface integrity in titanium alloy and nickel alloy machining and attempts to answer mechanisms systematically.First,to establish evaluation standard,the cutting mechanisms and performance improvement behavior covering antifriction,antiwear,tool failure,material removal,and surface formation of MQL were revealed.Second,the unique film formation and lubrication behaviors of CGNs in MQL turning,milling,and grinding are concluded.The influence law of molecular structure and micromorphology of CGNs was also answered and optimized options were recommended by considering diverse boundary conditions.Finally,in view of CGNs limitations in MQL,the future development direction is proposed,which needs to be improved in thermal stability of lubricant,activity of CGNs,controllable atomization and transportation methods,and intelligent formation of processing technology solutions.
基金Supported by National Key Research and Development Program of China(Grant No.2020YFB2010500)National Natural Science Foundation of China(Grant Nos.51975305,52105457)Shandong Provincial Natural Science Foundation of China(Grant No.ZR2020KE027).
文摘Cutting fluid is crucial in ensuring surface quality and machining accuracy during machining.However,traditional mineral oil-based cutting fluids no longer meet modern machining’s health and environmental protection require-ments.As a renewable,pollution-free alternative with excellent processing characteristics,vegetable oil has become an inevitable replacement.However,vegetable oil lacks oxidation stability,extreme pressure,and antiwear proper-ties,which are essential for machining requirements.The physicochemical characteristics of vegetable oils and the improved methods’application mechanism are not fully understood.This study aims to investigate the effects of viscosity,surface tension,and molecular structure of vegetable oil on cooling and lubricating properties.The mechanisms of autoxidation and high-temperature oxidation based on the molecular structure of vegetable oil are also discussed.The study further investigates the application mechanism and performance of chemical modification and antioxidant additives.The study shows that the propionic ester of methyl hydroxy-oleate obtained by epoxidation has an initial oxidation temperature of 175℃.The application mechanism and extreme pressure performance of conventional extreme pressure additives and nanoparticle additives were also investigated to solve the problem of insufficient oxidation resistance and extreme pressure performance of nanobiological lubricants.Finally,the study discusses the future prospects of vegetable oil for chemical modification and nanoparticle addition.The study provides theoretical guidance and technical support for the industrial application and scientific research of vegetable oil in the field of lubrication and cooling.It is expected to promote sustainable development in the manufacturing industry.
基金Supported by National Key Research and Development Program of China(Grant No.2020YFB2010500)National Natural Science Foundation of China(Grant Nos.51975305,51905289)+2 种基金Shandong Provincial Major Science and Technology Innovation Engineering Projects of China(Grant No.2019JZZY020111)Shandong Provincial Natural Science Foundation of China(Grant Nos.ZR2020KE027,ZR2020ME158,ZR2019PEE008)Applied Basic Research Youth Project of Qingdao Science and Technology Plan(Grant No.19-6-2-63-cg)。
文摘The application of cutting fluid in the field of engineering manufacturing has a history of hundreds of years,and it plays a vital role in the processing efficiency and surface quality of parts.Among them,water-based cutting fluid accounts for more than 90%of the consumption of cutting fluid.However,long-term recycling of water-based cutting fluid could easily cause deterioration,and the breeding of bacteria could cause the cutting fluid to fail,increase manufacturing costs,and even endanger the health of workers.Traditional bactericides could improve the biological stability of cutting fluids,but they are toxic to the environment and do not conform to the development trend of low-carbon manufacturing.Low-carbon manufacturing is inevitable and the direction of sustainable manufacturing.The use of nanomaterials,transition metal complexes,and physical sterilization methods on the bacterial cell membrane and genetic material could effectively solve this problem.In this article,the mechanism of action of additives and microbial metabolites was first analyzed.Then,the denaturation mechanism of traditional bactericides on the target protein and the effect of sterilization efficiency were summarized.Further,the mechanism of nanomaterials disrupting cell membrane potential was discussed.The effects of lipophilicity and the atomic number of transition metal complexes on cell membrane penetration were also summarized,and the effects of ultraviolet rays and ozone on the destruction of bacterial genetic material were reviewed.In other words,the bactericidal performance,hazard,degradability,and economics of various sterilization methods were comprehensively evaluated,and the potential development direction of improving the biological stability of cutting fluid was proposed.
基金financially supported by the National Natural Science Foundation of China(Grant Nos.51975305,51905289,52105457 and 52105264)National key Research and Development plan(2020YFB2010500)+2 种基金Key projects of Shandong Natural Science Foundation of China(Grant Nos.ZR2020KE027,ZR2020ME158 and ZR2021QE116)Major Science and technology innovation engineering projects of Shandong Province(Grant No.2019JZZY020111)Source Innovation Project of Qingdao West Coast New Area(Grant Nos.2020-97 and 2020-98).
文摘Metal cutting fluids(MCFs)under flood conditions do not meet the urgent needs of reducing carbon emission.Biolubricant-based minimum quantity lubrication(MQL)is an effective alternative to flood lubrication.However,pneumatic atomization MQL has poor atomization properties,which is detrimental to occupational health.Therefore,electrostatic atomization MQL requires preliminary exploratory studies.However,systematic reviews are lacking in terms of capturing the current research status and development direction of this technology.This study aims to provide a comprehensive review and critical assessment of the existing understanding of electrostatic atomization MQL.This research can be used by scientists to gain insights into the action mechanism,theoretical basis,machining performance,and development direction of this technology.First,the critical equipment,eco-friendly atomization media(biolubricants),and empowering mechanisms of electrostatic atomization MQL are presented.Second,the advanced lubrication and heat transfer mechanisms of biolubricants are revealed by quantitatively comparing MQL with MCF-based wet machining.Third,the distinctive wetting and infiltration mechanisms of electrostatic atomization MQL,combined with its unique empowering mechanism and atomization method,are compared with those of pneumatic atomization MQL.Previous experiments have shown that electrostatic atomization MQL can reduce tool wear by 42.4%in metal cutting and improve the machined surface Ra by 47%compared with pneumatic atomization MQL.Finally,future development directions,including the improvement of the coordination parameters and equipment integration aspects,are proposed.
基金Supported by National Natural Science Foundation of China(Grant Nos.51806112,51975305)PhD Research Startup Foundation of Qingdao University of Technology,China(Grant Nos.JC2022-012,20312008).
文摘Nanofluid minimum quantity lubrication(NMQL)is a green processing technology.Cottonseed oil is suitable as base oil because of excellent lubrication performance,low freezing temperature,and high yield.Al_(2)O_(3)nanoparticles improve not only the heat transfer capacity but also the lubrication performance.The physical and chemical proper-ties of nanofluid change when Al_(2)O_(3)nanoparticles are added.However,the effects of the concentration of nanofluid on lubrication performance remain unknown.Furthermore,the mechanisms of interaction between Al_(2)O_(3)nanoparti-cles and cottonseed oil are unclear.In this research,nanofluid is prepared by adding different mass concentrations of Al_(2)O_(3)nanoparticles(0,0.2%,0.5%,1%,1.5%,and 2%wt)to cottonseed oil during minimum quantity lubrication(MQL)milling 45 steel.The tribological properties of nanofluid with different concentrations at the tool/workpiece interface are studied through macro-evaluation parameters(milling force,specific energy)and micro-evaluation parameters(surface roughness,micro morphology,contact angle).The result show that the specific energy is at the minimum(114 J/mm^(3)),and the roughness value is the lowest(1.63μm)when the concentration is 0.5 wt%.The surfaces of the chip and workpiece are the smoothest,and the contact angle is the lowest,indicating that the tribological proper-ties are the best under 0.5 wt%.This research investigates the intercoupling mechanisms of Al_(2)O_(3)nanoparticles and cottonseed base oil,and acquires the optimal Al_(2)O_(3)nanofluid concentration to receive satisfactory tribological properties.
基金Supported by National Natural Science Foundation of China(Grant Nos.51975305,52105457,and 52205481)the Special Fund of Taishan Scholars Project(Grant No.tsqn202211179)+1 种基金Shandong Provincial Youth Talent Promotion Project(Grant No.SDAST2021qt12)Shandong Provincial Natural Science Foundation(Grant Nos.ZR2023QE057,ZR2022QE028,ZR2021QE116,and ZR2020KE027).
文摘Micro-grinding with a spherical grinding head has been deemed an indispensable method in high-risk surgeries, such as neurosurgery and spine surgery, where bone grinding has long been plagued by the technical bottleneck of mechanical stress-induced crack damage. In response to this challenge, the ultrasound-assisted biological bone micro-grinding novel process with a spherical grinding head has been proposed by researchers. Force modeling is a prerequisite for process parameter determination in orthopedic surgery, and the difculty in establishing and accurately predicting bone micro-grinding force prediction models is due to the geometric distribution of abrasive grains and the dynamic changes in geometry and kinematics during the cutting process. In addressing these critical needs and technical problems, the shape and protrusion heights of the wear particle of the spherical grinding head were frst studied, and the gradual rule of the contact arc length under the action of high-speed rotating ultrasonic vibration was proposed. Second, the mathematical model of the maximum thickness of undeformed chips under ultrasonic vibration of the spherical grinding head was established. Results showed that ultrasonic vibration can reduce the maximum thickness of undeformed chips and increase the range of ductile and bone meal removals, revealing the mechanism of reducing grinding force. Further, the dynamic grinding behavior of diferent layers of abrasive particles under diferent instantaneous interaction states was studied. Finally, a prediction model of micro-grinding force was established in accordance with the relationship between grinding force and cutting depth, revealing the mechanism of micro-grinding force transfer under ultrasonic vibration. The theoretical model’s average deviations are 10.37% in x-axis direction, 6.85% in y-axis direction, and 7.81% in z-axis direction compared with the experimental results. This study provides theoretical guidance and technical support for clinical bone micro-grinding.
文摘Minimum quantity Lubrication(MQL)is a sustainable lubrication system that is famous in many machining systems.It involve the spray of an infinitesimal amount of mist-like lubricants during machining processes.The MQL system is affirmed to exhibit an excellent machining performance,and it is highly economical.The nanofluids are understood to exhibit excellent lubricity and heat evacuation capability,compared to pure oil-based MQL system.Studies have shown that the surface quality and amount of energy expended in the grinding operations can be reduced considerably due to the positive effect of these nanofluids.This work presents an experimental study on the tribological performance of SiO_(2)nanofluid during grinding of Si_(3)N_(4)ceramic.The effect different grinding modes and lubrication systems during the grinding operation was also analyzed.Different concentrations of the SiO_(2)nanofluid was manufactured using canola,corn and sunflower oils.The quantitative evaluation of the grinding process was done based on the amount of grinding forces,specific grinding energy,frictional coefficient,and surface integrity.It was found that the canola oil exhibits optimal lubrication performance compared to corn oil,sunflower oil,and traditional lubrication systems.Additionally,the introduction of ultrasonic vibrations with the SiO_(2)nanofluid in MQL system was found to reduce the specific grinding energy,normal grinding forces,tangential grinding forces,and surface roughness by 65%,57%,65%,and 18%respectively.Finally,regression analysis was used to obtain an optimum parameter combinations.The observations from this work will aid the smooth transition towards ecofriendly and sustainable machining of engineering ceramics.
基金Supported by Shandong Provincial Natural Science Foundation of China(Grant Nos.ZR2022ME208,ZR2020QE181)National Natural Science Foundation of China(Grant Nos.51705272,52005281)+1 种基金China Postdoctoral Science Foundation(Grant No.2018M642628)111 project(Grant No.D21017).
文摘Graphene has superhigh thermal conductivity up to 5000 W/(m·K),extremely thin thickness,superhigh mechanical strength and nano-lamellar structure with low interlayer shear strength,making it possess great potential in mini-mum quantity lubrication(MQL)grinding.Meanwhile,ionic liquids(ILs)have higher thermal conductivity and better thermal stability than vegetable oils,which are frequently used as MQL grinding fluids.And ILs have extremely low vapor pressure,thereby avoiding film boiling in grinding.These excellent properties make ILs also have immense potential in MQL grinding.However,the grinding performance of graphene and ionic liquid mixed fluid under nano-fluid minimum quantity lubrication(NMQL),and its tribological mechanism on abrasive grain/workpiece grinding interface,are still unclear.This research firstly evaluates the grinding performance of graphene and ionic liquid mixed nanofluids(graphene/IL nanofluids)under NMQL experimentally.The evaluation shows that graphene/IL nanofluids can further strengthen both the cooling and lubricating performances compared with MQL grinding using ILs only.The specific grinding energy and grinding force ratio can be reduced by over 40%at grinding depth of 10μm.Work-piece machined surface roughness can be decreased by over 10%,and grinding temperature can be lowered over 50℃at grinding depth of 30μm.Aiming at the unclear tribological mechanism of graphene/IL nanofluids,molecular dynamics simulations for abrasive grain/workpiece grinding interface are performed to explore the formation mechanism of physical adsorption film.The simulations show that the grinding interface is in a boundary lubrication state.IL molecules absorb in groove-like fractures on grain wear flat face to form boundary lubrication film,and graphene nanosheets can enter into the grinding interface to further decrease the contact area between abrasive grain and workpiece.Compared with MQL grinding,the average tangential grinding force of graphene/IL nanofluids can decrease up to 10.8%.The interlayer shear effect and low interlayer shear strength of graphene nanosheets are the principal causes of enhanced lubricating performance on the grinding interface.EDS and XPS analyses are further carried out to explore the formation mechanism of chemical reaction film.The analyses show that IL base fluid happens chemical reactions with workpiece material,producing FeF_(2),CrF_(3),and BN.The fresh machined surface of workpiece is oxidized by air,producing NiO,Cr_(2)O_(3) and Fe_(2)O_(3).The chemical reaction film is constituted by fluorides,nitrides and oxides together.The combined action of physical adsorption film and chemical reaction film make graphene/IL nano-fluids obtain excellent grinding performance.
基金supported by the National Natural Science Foundation of China (Nos.52305477,52375447,52305474)Major Special Projects of Aero-engine and Gas Turbine (No.2017-VII-0002-0095)+4 种基金the Special Fund of Taishan Scholars Project (No.tsqn202211179)the Youth Talent Promotion Project in Shandong (No.SDAST2021qt12)the Natural Science Foundation of Shandong Province (Nos.ZR2023QE057,ZR2022QE028,ZR2021QE116,and ZR2020KE027)Qingdao Science and Technology Planning Park Cultivation Plan (No.23-1-5-yqpy-17-qy)the Natural Science Foundation of Jiangsu Province (No.BK20210407).
文摘The machining surface integrity of aero-engine turbine disc slots has a significant impact on their fatigue life and service performance,and achieving efficiency and high-precision machining is still a great challenge.The high machining requirements of future aeroengine turbine disc slots will be difficult to satisfy using the broaching method.In addition,existing methods of slot machin-ing face difficulties in ensuring surface integrity.This study explored a cup shaped electroplated Cubic Boron Nitride(CBN)abrasive wheel for profile grinding the turbine disc slots of FGH96 powder metallurgy superalloy.The matrix structure of the cup shaped abrasive wheel was designed and verified.A profile grinding experiment was conducted for fir-tree slots on a five-axis machining center.The accuracy and the surface integrity were analyzed.Results show that the key dimension detection results of the slots were within the allowable tolerance range.Meanwhile,an average sur-face roughness Ra of 0.55μm was achieved,the residual stress was compressive,the plastic defor-mation layer thickness was less than 5μm,and the hardening layer thickness was less than 20μm.The research findings provide a new approach to machining the slots of aviation engine turbine discs and guidance for the high-quality processing of complex components.
基金Supported by Special Fund of Taishan Scholars Project(Grant No.tsqn202211179)National Natural Science Foundation of China(Grant No.52105457)+2 种基金Shandong Provincial Young Talent of Lifting Engineering for Science and Technology(Grant No.SDAST2021qt12)National Natural Science Foundation of China(Grant No.52375447)China Postdoctoral Science Foundation Funded Project(Grant No.2023M732826).
文摘The surface morphology and roughness of a workpiece are crucial parameters in grinding processes.Accurate prediction of these parameters is essential for maintaining the workpiece’s surface integrity.However,the randomness of abrasive grain shapes and workpiece surface formation behaviors poses significant challenges,and accuracy in current physical mechanism-based predictive models is needed.To address this problem,by using the random plane method and accounting for the random morphology and distribution of abrasive grains,this paper proposes a novel method to model CBN grinding wheels and predict workpiece surface roughness.First,a kinematic model of a single abrasive grain is developed to accurately capture the three-dimensional morphology of the grinding wheel.Next,by formulating an elastic deformation and formation model of the workpiece surface based on Hertz theory,the variation in grinding arc length at different grinding depths is revealed.Subsequently,a predictive model for the surface morphology of the workpiece ground by a single abrasive grain is devised.This model integrates the normal distribution model of abrasive grain size and the spatial distribution model of abrasive grain positions,to elucidate how the circumferential and axial distribution of abrasive grains influences workpiece surface formation.Lastly,by integrating the dynamic effective abrasive grain model,a predictive model for the surface morphology and roughness of the grinding wheel is established.To examine the impact of changing the grit size of the grinding wheel and grinding depth on workpiece surface roughness,and to validate the accuracy of the model,experiments are conducted.Results indicate that the predicted three-dimensional morphology of the grinding wheel and workpiece surfaces closely matches the actual grinding wheel and ground workpiece surfaces,with surface roughness prediction deviations as small as 2.3%.
基金Major Project for New Generation of AI under Grant 2018AAA0100400in part by Scientific Research Fund of Hunan Provincial Education Department of China under Grant 21A0350,21C0439+4 种基金in part by the National Natural Science Foundation of China under Grant 61673355in part by the Fundamental Research Funds for the Central Universities,China University of Geosciences(Wuhan)under Grant CUGGC02in part by the Hubei Provincial Natural Science Foundation of China under Grant 2015CFA010in part by the high-performance computing platform of the China University of Geosciencesin part by the 111 projectunder Grant B17040.
文摘Pattern synthesise of antenna arrays is usually complicated optimization problems,while evolutionary algorithms(EAs)are promising in solving these problems.This paper does not propose a new EA,but does construct a new form of optimization problems.The new optimization formulation has two differences from the common ones.One is the objective function is the field error between the desired and the designed,not the usual amplitude error between the desired and the designed.This difference is beneficial to decrease complexity in some sense.The second difference is that the design variables are changed as phases of desired radiation field within shaped-region,instead of excitation parameters.This difference leads to the reduction of the number of design variables.A series of synthesis experiments including equally and unequally spaced linear arrays with different pattern shape requirements are applied,and the effectiveness and advantages of the proposed new optimization problems are validated.The results show that the proposing a new optimization formulation with less complexity is as significant as proposing a new algorithm.
文摘High-efficiency abrasive process with CBN grinding wheel is one of the important techniques of advanced manufacture. Combined with raw and finishing machining, it can attain high material removal rate like turning, milling and planning. The difficult-to-grinding materials can also be ground by means of this method with high performance. In the present paper, development status and latest progresses on high-efficiency abrasive machining technologies with CBN grinding wheel relate to high speed and super-high speed grinding, quick point-grinding, high efficiency deep-cut grinding, creep feed deep grinding, heavy-duty snagging and abrasive belt grinding were summarized. The efficiency and parameters range of these abrasive machining processes were compared. The key technologies of high efficiency abrasive machining, including grinding wheel, spindle and bearing, grinder, coolant supplying, installation and orientation of wheel and workpiece and safety defended, as well as intelligent monitor and NC grinding were investigated. It is concluded that high efficiency abrasive machining is a promising technology in the future.
基金Supported by National Natural Science Foundation of China(Grant Nos.52375447,52305477 and 52105457)Shandong Provincial Natural Science Foundation(Grant Nos.ZR2023QE057,ZR2024QE100 and ZR2024ME255)+2 种基金Qingdao Municipal Science and Technology Planning Park Cultivation Plan(Grant No.23-1-5-yqpy-17-qy)the Science and Technology SMEs Innovation Capacity Improvement Project of Shandong Province(Grant No.2022TSGC1115)the Special Fund of Taishan Scholars Project。
文摘During the metal cutting process,especially in continuous contact conditions like turning,the challenge of lubricants failing to effectively reach the cutting point remains unresolved.Micro-textured cutting tools offer a potential solution for tool-chip contact challenges.Inspired by the evolutionary achievements of the biosphere,micro-textures are expected to overcome lubrication limitations in cutting zones.Drawing on the anti-gravity water transport seen at the mouth edge of the Nepenthes plant,an innovative microchannel with Nepenthes-shaped contours was designed on the rake face to enable controlled lubricant transport.However,the dynamics of lubricant delivery on textured surfaces are not fully understood.This study first analyzed the microstructure and water transport mechanism of Nepenthes to reconstruct a micro-textured surface for controlled lubricant transport.A dynamic model was then developed to describe lubricant transport within open microchannels,with mathematical simulations predicting transport speed and flow distance.To validate this model,diffusion experiments of alumina soybean oil nanolubricant on polycrystalline diamond(PCD)cutting tool surfaces were conducted,showing an average prediction deviation of 5.01%.Compared with the classical Lucas-Washburn model,the new model improved prediction accuracy by 4.72%.Additionally,comparisons were made to examine droplet spreading and non-uniform diffusion on textured surfaces,revealing that the T2 surface exhibited the strongest unidirectional diffusion characteristics.The contact angle ratio,droplet unidirectional spreading ratio,and droplet spreading aspect ratio were 0.48,1.75,and 3.99,respectively.Finally,the anti-wear,friction-reducing,and efficiency-enhancing mechanisms of micro-textured surfaces in minimum quantity lubrication turning were analyzed.This approach may support continuous cutting of difficult-tomachine materials.
基金supported by the National Natural Science Foundation of China(Nos.51975305,51905289,52105264)the Key Project of Shandong Province,China(No.ZR2020KE027)+1 种基金the Major Research Project of Shandong Province,China(Nos.2019GGX104040 and 2019GSF108236)the Natural Science Foundation of Shandong Province,China(No.ZR2021QE116).
文摘Too high grinding force will lead to a large increase in specific grinding energy, resulting in high temperature in grinding zone, especially for the aerospace difficult cutting metal materials,seriously affecting the surface quality and accuracy. At present, the theoretical models of grinding force are mostly based on the assumption of uniform or simplified morphological characteristics of grains, which is inconsistent with the actual grains. Especially for non-engineering grinding wheel,most geometric characteristics of grains are ignored, resulting in the calculation accuracy that cannot guide practical production. Based on this, an improved grinding force model based on random grain geometric characteristics is proposed in this paper. Firstly, the surface topography model of CBN grinding wheel is established, and the effective grain determination mechanism in grinding zone is revealed. Based on the known grinding force model and mechanical behavior of interaction between grains and workpiece in different stages, the concept of grain effective action area is proposed. The variation mechanism of effective action area under the influence of grain geometric and spatial characteristics is deeply analyzed, and the calculation method under random combination of five influencing parameters is obtained. The numerical simulation is carried out to reveal the dynamic variation process of grinding force in grinding zone. In order to verify the theoretical model, the experiments of dry grinding Ti-6Al-4 V are designed. The experimental results show that under different machining parameters, the results of numerical calculation and experimental measurement are in good agreement, and the minimum error value is only 2.1 %, which indicates that the calculation accuracy of grinding force model meets the requirements and is feasible. This study will provide a theoretical basis for optimizing the wheel structure, effectively controlling the grinding force range, adjusting the grinding zone temperature and improving the workpiece machining quality in the industrial grinding process.
