Ultraprecision machining of titanium alloy(Ti-6Al-4V)remains challenging due to its low thermal conductivity,pronounced elastic recovery,and tool-workpiece adhesion,all of which degrade surface integrity and accelerat...Ultraprecision machining of titanium alloy(Ti-6Al-4V)remains challenging due to its low thermal conductivity,pronounced elastic recovery,and tool-workpiece adhesion,all of which degrade surface integrity and accelerate tool wear.This study systematically investigates the effect of a weak magnetic field(~0.015 T)on the single-point diamond turning and microgroove machining of Ti-6Al-4V flat surfaces,microgroove arrays,and microstructures.Four machining conditions were designed to decouple the magnetic field effect:no field(nM-nM),field applied only during microgroove cutting(nM-M),field applied only during finish turning(M-nM),and field applied throughout(M-M).Theoretical analyses and experiments have demonstrated that the rotation of the conductive titanium alloy within a magnetic field induces eddy currents,generating Lorentz damping,which suppresses vibrations in Y/Z directions,enhances cutting stability,and improves surface finish.The results showed that magnetic-field assistance significantly reduces both the principal cutting forces and noise levels,and that performance under M-nM conditions surpasses that under nM-M conditions,suggesting that the finishcutting process exerts a stronger influence on the quality of microgroove machining.Microstructures machined under M-M conditions exhibit exceptional dimensional accuracy and uniformity,with groove depths approaching a nominal value of 4μm(reaching~3.98μm under the M-M conditions)and minimal burrs or microcracks forming at boundaries.The findings enhance the understanding of the magnetic field-assisted ultraprecision cutting of titanium alloys,enabling the manufacturing of high-quality micro/nanostructures for applications in aerospace,biomedicine,and optical components.展开更多
Additive manufacturing,particularly 3D printing,has revolutionized the manufacturing industry by allowing the production of complex and intricate parts at a lower cost and with greater efficiency.However,3D-printed pa...Additive manufacturing,particularly 3D printing,has revolutionized the manufacturing industry by allowing the production of complex and intricate parts at a lower cost and with greater efficiency.However,3D-printed parts frequently require post-processing or integration with other machining technologies to achieve the desired surface finish,accuracy,and mechanical properties.Ultra-precision machining(UPM)is a potential machining technology that addresses these challenges by enabling high surface quality,accuracy,and repeatability in 3D-printed components.This study provides an overview of the current state of UPM for 3D printing,including the current UPM and 3D printing stages,and the application of UPM to 3D printing.Following the presentation of current stage perspectives,this study presents a detailed discussion of the benefits of combining UPM with 3D printing and the opportunities for leveraging UPM on 3D printing or supporting each other.In particular,future opportunities focus on cutting tools manufactured via 3D printing for UPM,UPM of 3D-printed components for real-world applications,and post-machining of 3D-printed components.Finally,future prospects for integrating the two advanced manufacturing technologies into potential industries are discussed.This study concludes that UPM is a promising technology for 3D-printed components,exhibiting the potential to improve the functionality and performance of 3D-printed products in various applications.It also discusses how UPM and 3D printing can complement each other.展开更多
基金financial supports from Young Scientist Fund of National Natural Science Foundation of China(Project No.52205498/K-ZGFT)the State Key Laboratory in Hong Kong from the Innovation and Technology Commission(ITC)of the Government of the Hong Kong Special Administrative Region(HKSAR),China+2 种基金the General Research Fund(GRF)of the Research Grants Council(RGC)of the Hong Kong Special Administrative Region(HKSAR),China(Project No.PolyU 15220724)the Shenzhen Key Technology Breakthrough Project(No.Z2022N074)Shenzhen Engineering Research Center for Semiconductor-specific Equipment and the Research Committee of The Hong Kong Polytechnic University(Project code:RKWR).
文摘Ultraprecision machining of titanium alloy(Ti-6Al-4V)remains challenging due to its low thermal conductivity,pronounced elastic recovery,and tool-workpiece adhesion,all of which degrade surface integrity and accelerate tool wear.This study systematically investigates the effect of a weak magnetic field(~0.015 T)on the single-point diamond turning and microgroove machining of Ti-6Al-4V flat surfaces,microgroove arrays,and microstructures.Four machining conditions were designed to decouple the magnetic field effect:no field(nM-nM),field applied only during microgroove cutting(nM-M),field applied only during finish turning(M-nM),and field applied throughout(M-M).Theoretical analyses and experiments have demonstrated that the rotation of the conductive titanium alloy within a magnetic field induces eddy currents,generating Lorentz damping,which suppresses vibrations in Y/Z directions,enhances cutting stability,and improves surface finish.The results showed that magnetic-field assistance significantly reduces both the principal cutting forces and noise levels,and that performance under M-nM conditions surpasses that under nM-M conditions,suggesting that the finishcutting process exerts a stronger influence on the quality of microgroove machining.Microstructures machined under M-M conditions exhibit exceptional dimensional accuracy and uniformity,with groove depths approaching a nominal value of 4μm(reaching~3.98μm under the M-M conditions)and minimal burrs or microcracks forming at boundaries.The findings enhance the understanding of the magnetic field-assisted ultraprecision cutting of titanium alloys,enabling the manufacturing of high-quality micro/nanostructures for applications in aerospace,biomedicine,and optical components.
基金supported by the State Key Laboratories in Hong Kong,China,from the Innovation and Technology Commission(project code:BBR3)of the Government of the Hong Kong Special Administrative Region,Chinathe Research Office(project codes:BBXM and BBX)of The Hong Kong Polytechnic University,China+1 种基金the Project of Strategic Importance(project codes:1-ZE0G and SBBD)of The Hong Kong Polytechnic University,Chinaand the Research Committee(project code:RMAC)of The Hong Kong Polytechnic University,China。
文摘Additive manufacturing,particularly 3D printing,has revolutionized the manufacturing industry by allowing the production of complex and intricate parts at a lower cost and with greater efficiency.However,3D-printed parts frequently require post-processing or integration with other machining technologies to achieve the desired surface finish,accuracy,and mechanical properties.Ultra-precision machining(UPM)is a potential machining technology that addresses these challenges by enabling high surface quality,accuracy,and repeatability in 3D-printed components.This study provides an overview of the current state of UPM for 3D printing,including the current UPM and 3D printing stages,and the application of UPM to 3D printing.Following the presentation of current stage perspectives,this study presents a detailed discussion of the benefits of combining UPM with 3D printing and the opportunities for leveraging UPM on 3D printing or supporting each other.In particular,future opportunities focus on cutting tools manufactured via 3D printing for UPM,UPM of 3D-printed components for real-world applications,and post-machining of 3D-printed components.Finally,future prospects for integrating the two advanced manufacturing technologies into potential industries are discussed.This study concludes that UPM is a promising technology for 3D-printed components,exhibiting the potential to improve the functionality and performance of 3D-printed products in various applications.It also discusses how UPM and 3D printing can complement each other.
