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
Micro-grinding has been widely used in aerospace and other industry.However,the small diameter of the micro-grinding tool has limited its machining performance and efficiency.In order to solve the above problems,micro...Micro-grinding has been widely used in aerospace and other industry.However,the small diameter of the micro-grinding tool has limited its machining performance and efficiency.In order to solve the above problems,micro-structure has been applied on the micro-grinding tool.A morphology modeling has been established in this study to characterize the surface of microstructured micro-grinding tool,and the grinding performance of micro-structured micro-grinding tool has been analyzed through undeformed chip thickness,abrasive edge width,and effective distance between abrasives.Then deviation analysis,path optimization and parameter optimization of microchannel array precision grinding have been finished to improve processing quality and efficiency,and the deflection angle has the most obvious effects on the rectangular slot depth,micro-structured micro-grinding tool could reduce 10%surface roughness and 20%grinding force compared to original micro-grinding tool.Finally,the microchannel array has been machined with a size deviation of 2μm and surface roughness of 0.2μm.展开更多
SiC-reinforced aluminum matrix(SiCp/Al)composite is widely utilized in the aerospace,automotive,and electronics industries due to the combination of ceramic hardness and metal toughness.However,the significant dispari...SiC-reinforced aluminum matrix(SiCp/Al)composite is widely utilized in the aerospace,automotive,and electronics industries due to the combination of ceramic hardness and metal toughness.However,the significant disparity in properties between SiC particles and the aluminum matrix results in severe tool wear and diminished surface quality during conventional machining.This study proposes an environmentally friendly and clean dry electrical discharge assisted grinding process as an efficient and low-damage machining method for SiCp/Al.An experimental platform was set up to study the impact of grinding and discharge process parameters on surface quality.The study compared the chip formation mechanism and surface quality between dry electrical discharge assisted grinding and conventional grinding,revealing relationships between surface roughness,grinding force,grinding temperature,and related parameters.The results indicate that the proposed grinding method leads to smaller chip sizes,lower grinding forces and temperatures,and an average reduction of 19.2%in surface roughness compared to conventional grinding.The axial,tangential,and normal grinding forces were reduced by roughly 10.5%,37.8%,and 23.0%,respectively.The optimized process parameters were determined to be N=2500 r/min,vf=30 mm/min,a=10μm,E=15 V,f=5000 Hz,dc=80%,resulting in a surface roughness of 0.161μm.展开更多
The undeformed chip thickness and grinding force are key parameters for revealing the material removal mechanism in the grinding process.However,they are difficult to be well expressed due to the ununiformed protrusio...The undeformed chip thickness and grinding force are key parameters for revealing the material removal mechanism in the grinding process.However,they are difficult to be well expressed due to the ununiformed protrusion height and random position distribution of abrasive grains on the abrasive wheel surface.This study investigated the distribution of undeformed chip thickness and grinding force considering the non-uniform characteristics of abrasive wheel in the grinding of K4002 nickel-based superalloy.First,a novel grinding force model was established through a kinematic-geometric analysis and a grain-workpiece contact analysis.Then,a series of grinding experiments were conducted for verifying the model.The results indicate that the distribution of undeformed chip thickness is highly consistent with the Gaussian distribution formula.The increase in the grinding depth mainly leads to an increase in the average value of Gaussian distribution.On the contrary,the increase in the workpiece infeed speed or the decrease in the grinding speed mainly increases the standard deviation of Gaussian distribution.The average and maximum errors of the grinding force model are 4.9%and 14.6%respectively,indicating that the model is of high predication accuracy.展开更多
The gears of new energy vehicles are required to withstand higher rotational speeds and greater loads,which puts forward higher precision essentials for gear manufacturing.However,machining process parameters can caus...The gears of new energy vehicles are required to withstand higher rotational speeds and greater loads,which puts forward higher precision essentials for gear manufacturing.However,machining process parameters can cause changes in cutting force/heat,resulting in affecting gear machining precision.Therefore,this paper studies the effect of different process parameters on gear machining precision.A multi-objective optimization model is established for the relationship between process parameters and tooth surface deviations,tooth profile deviations,and tooth lead deviations through the cutting speed,feed rate,and cutting depth of the worm wheel gear grinding machine.The response surface method(RSM)is used for experimental design,and the corresponding experimental results and optimal process parameters are obtained.Subsequently,gray relational analysis-principal component analysis(GRA-PCA),particle swarm optimization(PSO),and genetic algorithm-particle swarm optimization(GA-PSO)methods are used to analyze the experimental results and obtain different optimal process parameters.The results show that optimal process parameters obtained by the GRA-PCA,PSO,and GA-PSO methods improve the gear machining precision.Moreover,the gear machining precision obtained by GA-PSO is superior to other methods.展开更多
In ball milling,the process parameters are decisive in influencing the quality and performance of the final ball-milled product,and crucial but often neglected is the ratio of the grinding balls in terms of their size...In ball milling,the process parameters are decisive in influencing the quality and performance of the final ball-milled product,and crucial but often neglected is the ratio of the grinding balls in terms of their size.Here,for a given number of large grinding balls,the ratio of large to small ones is set to 1:2,1:3,1:4,and 1:5 by altering the number of small ones,and how this affects the morphology,structure,and electrochemical properties of ball-milled graphene nanosheets is investigated.The results show that changing the ball ratio causes distinct changes in the morphology,structure,and properties of the graphene nanosheets.Increasing the number of small(6 mm)grinding balls decreases the nanosheet grain size monotonically;meanwhile,the crystal plane spacing,defect density,and specific surface area increase and then decrease,but the graphitization degree decreases and then increases.Ball-milled samples are then used as anodes for lithium-ion batteries,and both the specific capacity and rate capability exhibit the same trend of increase and then decrease.The ball ratio of 1:3 gives the best electrochemical performance,i.e.,a reversible specific capacity of 262.09 mA·h/g at a current density of 100 mA/g,and even after 2000 cycles at 2000 mA/g,the reversible specific capacity is 87.4%of the optimal value.展开更多
Co-associated rare earth elements(lanthanide and yttrium,REY)in coal and its by-products have been considered important potential nontraditional rare earth sources.In this study,a coal gangue sample collected from a c...Co-associated rare earth elements(lanthanide and yttrium,REY)in coal and its by-products have been considered important potential nontraditional rare earth sources.In this study,a coal gangue sample collected from a coal processing plant in Jinsha County of Guizhou Province,southwest China,was used as the research object.The content,modes of occurrence,and extraction(acid leaching after pretreatment of selective grinding,tailings discarding,and alkali roasting)of REY from the sample were analyzed.The result shows that the content of REY(1038.26μg/g)in pyrite and quartz is low but mainly enriched in kaolinite.Under the following conditions of a filling ratio of 40%(grinding media steel ball)and grinding time of 8 min,selective grinding pretreatment is applied to achieve 176.95μg/g(yield 24.08%)and 1104.93μg/g(yield 75.92%)of REY in+2 mm and-2 mm fractions,respectively.Thus,the-2 mm coal gangue fraction is selected,used as the feed,and roasted and leached with HCl.When Na_(2)CO_(3)and NaCl are separately used as roasting activators,the REY leaching ratios are 91.41%and 68.88%,respectively,under the optimum conditions.The contents of REY in the final leachate are 1010.02 and 761.08μg/g when Na_(2)CO_(3)and NaCl are used,respectively.The two REY contents are relatively higher than the impurity ions in the leachate,which facilitates further REY separation.The mechanism study reveals that high-temperature roasting increases the pore size and the total pore area of the gangue,which promotes leachate penetration and improves reaction efficiency.In addition,roasting facilitates the reaction between the sodium salt activator and kaolinite and other aluminosilicate minerals in the coal gangue to generate soluble salts,thus releasing REY into the solution.The appropriate roasting temperature transforms the activator into a molten state.Thus,the reaction between coal gangue and activator is a solid-liquid reaction rather than a solid-solid reaction,which improves the efficiency of the chemical reaction.展开更多
The machining precision of blades is critical to the service performance of aero engines.The Leading Edge(LE) of high-pressure compressor blades poses a challenge for precision machining due to its thin size, high deg...The machining precision of blades is critical to the service performance of aero engines.The Leading Edge(LE) of high-pressure compressor blades poses a challenge for precision machining due to its thin size, high degree of bending, and significant change of curvature. Aimed at optimizing the machining error, this paper presents a framework that integrates toolpath planning and process parameter regulation. Firstly, an Iterative Subdivision Algorithm(ISA) for clamped Bspline curve is proposed, based on which toolpath planning method towards the LE is developed.Secondly, the removal effect of Cutter Contact(CC) point on the sampling points is investigated in the calculation of grinding dwell time by traversing in u-v space. A global material removal model is constructed for the solution. Thirdly, the previous two steps are interconnected based on the Improved Whale Optimization Algorithm(IWOA), and the optimal parameter combination is searched using the Root Mean Square Error(RMSE) of the machining error as the objective function. Based on this, the off-line programming and robotic grinding experiments are carried out. The experimental results show that the proposed method with error optimization can achieve 0.0143 mm mean value and 0.0160 mm standard deviations of LE surface error, which is an improvement of32.5% and 33.9%, respectively, compared with previous method.展开更多
Workpiece rotational grinding is widely used in the ultra-precision machining of hard and brittle semiconductor materials,including single-crystal silicon,silicon carbide,and gallium arsenide.Surface roughness and sub...Workpiece rotational grinding is widely used in the ultra-precision machining of hard and brittle semiconductor materials,including single-crystal silicon,silicon carbide,and gallium arsenide.Surface roughness and subsurface damage depth(SDD)are crucial indicators for evaluating the surface quality of these materials after grinding.Existing prediction models lack general applicability and do not accurately account for the complex material behavior under grinding conditions.This paper introduces novel models for predicting both surface roughness and SDD in hard and brittle semiconductor materials.The surface roughness model uniquely incorporates the material’s elastic recovery properties,revealing the significant impact of these properties on prediction accuracy.The SDD model is distinguished by its analysis of the interactions between abrasive grits and the workpiece,as well as the mechanisms governing stress-induced damage evolution.The surface roughness model and SDD model both establish a stable relationship with the grit depth of cut(GDC).Additionally,we have developed an analytical relationship between the GDC and grinding process parameters.This,in turn,enables the establishment of an analytical framework for predicting surface roughness and SDD based on grinding process parameters,which cannot be achieved by previous models.The models were validated through systematic experiments on three different semiconductor materials,demonstrating excellent agreement with experimental data,with prediction errors of 6.3%for surface roughness and6.9%for SDD.Additionally,this study identifies variations in elastic recovery and material plasticity as critical factors influencing surface roughness and SDD across different materials.These findings significantly advance the accuracy of predictive models and broaden their applicability for grinding hard and brittle semiconductor materials.展开更多
Silicon carbide(SiC)ceramics are extensively utilized in aerospace,national defense,and petrochemical industries due to their superior physical and chemical properties.The processing of bulk SiC ceramics necessitates ...Silicon carbide(SiC)ceramics are extensively utilized in aerospace,national defense,and petrochemical industries due to their superior physical and chemical properties.The processing of bulk SiC ceramics necessitates precise and efficient grinding techniques to produce components with satisfactory functionality.However,the inherent high hardness and brittleness of SiC ceramics present significant challenges during grinding,leading to severe brittle fracture and tool wear that compromise both surface integrity and production efficiency.Although ductile-regime grinding of SiC ceramics can be achieved by enhancing machine tool accuracy and stiffness while optimizing wheel performance alongside appropriate selection of process parameters,a comprehensive summary of the mechanisms underlying damage evolution during grinding is lacking,and a mature grinding process for SiC ceramics has yet to be developed.To bridge this gap,the sintering technologies,mechanical properties,and microstructures of SiC ceramics were briefly covered.The grinding-induced damage mechanism and low-damage grinding technologies of SiC ceramics were summarized.The fundamental science underlying the ductile deformation and removal mechanisms of brittle solids was emphasized.Additionally,attention was directed towards the critical role of hybrid energy field grinding in minimizing brittle damages and promoting removal efficiency.This review not only elucidates the intrinsic interactions between the work material and abrasives,but also offers valuable insights for optimizing the grinding processes of brittle solids.展开更多
Styrene-butadiene-styrene(SBS)modified asphalt(SA)has long found effective applications in road construction materials.When combined with fillers,SBS-modified asphalt has demonstrated promising resistance to fatigue c...Styrene-butadiene-styrene(SBS)modified asphalt(SA)has long found effective applications in road construction materials.When combined with fillers,SBS-modified asphalt has demonstrated promising resistance to fatigue cracking caused by temperature fluctuations and aging.In this study,molybdenum disulfide(MoS_(2))and polyphosphoric acid(PPA)were ground in naphthenic oil(NO)and subjected to mechanical activation to create PPAmodified MoS_(2),referred to as OMS-PPA.By blending various ratios of OMS-PPA with SBS-modified asphalt,composite-modified asphalts were successfully developed to enhance their overall properties.To assess the mechanical characteristics and stability of these modified asphalts,various methods were employed,including penetration factor,flow activation energy,fluorescence microscopy,and dynamic shear rheology.Additionally,the short-term aging performance was evaluated using Fourier transform infrared(FTIR)spectroscopy and nanoindentation tests.The results revealed a 3.7%decrease in the penetration-temperature coefficient for SAOMS compared to SA,while 1-SA-OMS-PPA showed an even greater reduction of 7.1%.Furthermore,after short-term aging,carboxyl group generation in SA increased by 5.93%,while SA-OMS exhibited a smaller rise of 1.36%,and 1-SA-OMS-PPA saw an increase of just 0.93%.The study also highlighted significant improvements in the hardness of these materials.The hardness change ratio for SA-OMS decreased by 43.08%,while the ratio for 1-SA-OMS-PPA saw a notable reduction of 65.16% compared to unmodified SA.These findings suggest that OMS-PPA contributed to improvements in temperature sensitivity,particle dispersibility,and resistance to shortterm aging in asphalts.The results hold significant promise for the future development of advanced asphalt-based materials with potential high-value applications in flexible pavements for highways.展开更多
Sapphire hemispherical domes are machined through milling and shaping using brazed diamond tools.A mathematical model describing roughness for this processing method is established,and the relationship between roughne...Sapphire hemispherical domes are machined through milling and shaping using brazed diamond tools.A mathematical model describing roughness for this processing method is established,and the relationship between roughness and its influencing factors is analyzed.Experiments on the hemispherical dome shaping process are conducted to validate the model,analyzing the variation in roughness under different tool and workpiece rotational speeds.The results are consistent with the predictions of the established roughness model,suggesting that the model can be used to guide subsequent process experiments.Milling and shaping efficiency using brazed diamond tools typically can reach 14 g/min.The machined sapphire surfaces exhibit relatively few microcracks and minimal damage,with almost all exclusively visible grooves resulting from brittle fracture removal.The surface roughness after machining is below 2.5μm.Milling sapphire domes with brazed diamond tools represents a novel shaping technique characterized by high efficiency and high quality.展开更多
The utilization of ironsand for preparing oxidized pellets poses challenges,including slow oxidation and low consolidation strength.The effects and function mechanisms of high-pressure grinding roll(HPGR)pretreatment ...The utilization of ironsand for preparing oxidized pellets poses challenges,including slow oxidation and low consolidation strength.The effects and function mechanisms of high-pressure grinding roll(HPGR)pretreatment on the oxidation and consolidation of ironsand pellets were investigated,and the energy utilization efficiency of HPGR with different roller pressure intensities was evaluated.The results indicate that HPGR pretreatment at 8 MPa improves the ironsand properties,with the specific surface area increasing by 740 cm^(2) g^(-1) and mechanical energy storage increasing by 2.5 kJ mol^(-1),which is conducive to oxidation and crystalline connection of particles.As roller pressure intensity increases to 16 MPa,more mechanical energy of HPGR is applied for crystal activation,with mechanical energy storage further rising by 18.1 kJ mol^(-1).The apparent activation energy for pellet oxidation initially decreases and then increases,reaching a minimum at 12 MPa.Simultaneously,the roasted pellets porosity decreases by 2.8%,while the compressive strength increases by 789 N.At higher roller pressure intensity,the densely connected structure between particles impedes gas diffusion within the pellets,diminishing the beneficial effects of HPGR on pellet oxidation.Moreover,excessive roller pressure intensity decreases the HPGR energy utilization efficiency.The optimal HPGR roller pressure intensity for ironsand is 12 MPa,at which the specific surface area increases by 790 cm^(2) g^(-1),mechanical energy storage increases by 10.6 kJ mol^(-1),the compressive strength of roasted pellets rises to 2816 N,and the appropriate preheating and roasting temperatures decrease by 250 and 125°C,respectively.展开更多
Because the grinding temperature is high when grinding using conventional disordered grinding wheels,the grinding quality improvement is limited when using single abrasive ordered grinding wheels,and the wheel prepara...Because the grinding temperature is high when grinding using conventional disordered grinding wheels,the grinding quality improvement is limited when using single abrasive ordered grinding wheels,and the wheel preparation process is complex and costly when using microstructured grinding wheels,abrasive groups ordered grinding wheels are widely investigated.However,there is a paucity of systematic analyses and comprehensive reviews focused on abrasive groups ordered grinding wheels.Therefore,this paper defines abrasive groups ordered grinding wheels and classifies them,based on their unique characteristics,into groups such as abrasive blocks ordered grinding wheel,fine grain structured grinding wheel,abrasive clusters ordered grinding wheel,and abrasive fibers ordered grinding wheel.We provide an overview of the latest advances in wheel structures,preparation methods,and abrasive selection for various types of abrasive groups ordered grinding wheels.Furthermore,we conduct a comparative analysis of the existing types,significant advantages,and challenges associated with the four types of abrasive groups ordered grinding wheels.Looking ahead,given the potential of abrasive groups ordered grinding wheels in reducing grinding force and temperature,we recommend further exploration of their application in combination with special processing techniques.This could pave the way for the development of machining processes that are more environmentally friendly,energy-efficient,and precise.展开更多
This research aimed to overcome challenges such as high costs,lengthy optimization time,and low efficiency in resolving issues related to wheel-rail contact,rail wear,and vehicle dynamics.Based on the wheel-rail conta...This research aimed to overcome challenges such as high costs,lengthy optimization time,and low efficiency in resolving issues related to wheel-rail contact,rail wear,and vehicle dynamics.Based on the wheel-rail contact parameters,an optimal design method for rail grinding target profile is proposed from wear profile measurement to grinding profile design according to the actual railway track and vehicle operating conditions.We utilized Isight to create a simulation test and developed an RBF proxy model that incorporated both mechanical and geometric aspects of wheel-rail contact.By integrating rail modeling,wheel-rail contact analysis,and multi-objective optimization,we established a rail grinding optimization model that was solved using the NSGA-II algorithm.After optimization,the study achieved a 31.863%reduction in average contact stress,a 70.5%reduction in matching wear work,and a 100.391%increase in the difference in rolling radius between the wheel and rail.展开更多
Any product must undergo precise manufacturing before use.The damage incurred during the manufacturing process can significantly impact the residual strength of the product post-manufacturing.However,the relationship ...Any product must undergo precise manufacturing before use.The damage incurred during the manufacturing process can significantly impact the residual strength of the product post-manufacturing.However,the relationship between residual bending strength and manufacturing-induced damage remains unclear,despite being a crucial parameter for assessing material service life and performance,leading to a decrease in product performance reliability.This study focuses on investigating the impact of crack generation on residual bending strength through theoretical and experimental analyses of scratching,grinding,and three-point bending.The research first elucidates the forms and mechanisms of material damage through scratch experiments.Subsequently,using resin-bonded and electroplated wheels as case studies,the influence of different process parameters on grinding damage and residual bending strength is explored.The reduction of brittle removal can lead to a 50%–60%decrease in residual bending strength.Lastly,a model is developed to delineate the relationship between processing parameters and the residual bending strength of the product,with the model exhibiting an error margin of less than 11%.This model clearly reveals the effect of crack generation under different process parameters on residual flexural strength.展开更多
Compared with sintered silicon carbides(SiC),highly-orientated 3C-SiC by CVD methods boast out-of-plane orientation uniformity,which ensures that such materials produce lower surface damage.Through the electrolytic in...Compared with sintered silicon carbides(SiC),highly-orientated 3C-SiC by CVD methods boast out-of-plane orientation uniformity,which ensures that such materials produce lower surface damage.Through the electrolytic in-process dressing(ELID)grinding technique,the differences in grinding behaviors between<110>and<111>-orientated 3C-SiC were investigated.Both highly-orientated 3C-SiC exhibited a grinding surface where brittle and ductile removal coexisted.Specifically,brittle removal regions were observed at grain boundaries,while ductile removal regions were observed within the grains.Further indentation experiments between the two 3C-SiC show that<111>-oriented 3C-SiC displays a larger critical cut depth of 28.99 nm,with 1.5 times higher than that of<110>-oriented 3C-SiC.The larger critical depth of cut contributes to more ductile removal regions with only a few brittle pits in the<111>-oriented 3C-SiC grinding surface.In addition,the subsurface deformation of<110>-oriented 3C-SiC was characterized by the presence of amorphous zones,dislocations and stacking faults.In contrast to the<111>-oriented,the<110>-oriented 3C-SiC tends to exhibit a brittle removal mode dominated by pits and cracks at the twin boundaries,as its pre-existing twins hinder the dislocation glide,resulting in stress concentration and thus forming cracks.展开更多
Machined surface integrity of workpieces in harsh environments has a remarkable influence on their performance.However,the complexity of the new type of machining hinders a comprehensive understanding of machined surf...Machined surface integrity of workpieces in harsh environments has a remarkable influence on their performance.However,the complexity of the new type of machining hinders a comprehensive understanding of machined surface integrity and its formation mechanism,thereby limiting the study of component performance.With increasing demands for high-quality machined workpieces in aerospace industry applications,researchers from academia and industry are increasingly focusing on post-machining surface characterization.The profile grinding test was conducted on a novel single-crystal superalloy to simulate the formation of blade tenons,and the obtained tenons were characterized for surface integrity elements under various operating conditions.Results revealed that ultrasonic vibration-assisted grinding(UVAG)led to multiple superpositions of abrasive grain trajectories,causing reduced surface roughness(an average reduction of approximately29.6%)compared with conventional grinding.After examining the subsurface layer of UVAG using transmission electron microscopy,the results revealed that the single-crystal tenon grinding subsurface layer exhibited a gradient evolution from the near-surface to the substrate.This evolution was characterized by an equiaxed nanocrystalline layer measuring 0.34μm,followed by a submicrocrystalline grain-forming zone spanning 0.6μm and finally,a constituent phase-twisted dis-torted deformation zone over 0.62μm.Under normal grinding conditions,the tenon exhibited low surface hardening(not exceeding 15%),and residual compressive stresses were observed on its surface.In cases where grinding burns occurred,a white layer appeared on the tenon's surface,which demonstrated varying thicknesses along the teeth from top to root due to thermal-force-structural coupling effects.Additionally,these burns introduced residual tensile stresses on the tenon's surface,potentially substantially affecting its fatigue life.This paper enhances our understanding of UVAG processes and establishes a foundation for their application in manufacturing singlecrystal turbine blades for next-generation aero-turbine engines.展开更多
The manufacturing industry is the core support for the development of the real economy.While promoting rapid economic growth,it also brings severe resource and environmental challenges.China's manufacturing indust...The manufacturing industry is the core support for the development of the real economy.While promoting rapid economic growth,it also brings severe resource and environmental challenges.China's manufacturing industry has ranked first in the world in terms of energy consumption,accounting for 56%of China's total energy consumption.Its electricity consumption exceeds 50%of the total social electricity consumption,and its carbon emissions reach 1.81 billion tons,accounting for 34% of the national total.Against this backdrop,enhancing the sustainability of high-end equipment manufacturing industries represented by aerospace has become a major strategic need for China's modernization,and it also provides strong support for solving global environmental problems.展开更多
Continuous Fiber-reinforced Metal Matrix Composites(CFMMCs),such as Si C fiberreinforced TC17 matrix composites(SiC_(f)/TC17),are renowned for their exceptional mechanical properties.However,their heterogeneous compos...Continuous Fiber-reinforced Metal Matrix Composites(CFMMCs),such as Si C fiberreinforced TC17 matrix composites(SiC_(f)/TC17),are renowned for their exceptional mechanical properties.However,their heterogeneous compositions present significant machining challenges,including fiber pullout,matrix cracking,and accelerated tool wear.Ultrasonic Vibration-Assisted Grinding(UVAG)has proven to be an effective technique for overcoming these challenges.The material removal mechanisms in UVAG,especially in composites with both ductile and brittle phases,remain poorly understood.To explore these issues,UVAG and Conventional Grinding(CG)experiments were conducted on SiC_(f)/TC17 along two grinding directions:fiber's transverse direction(FT)and fiber's longitudinal direction(FL).This paper aims to provide a new dynamic mechanical model and shed light on the complex removal mechanisms in CFMMCs,which are characterized by a near one-to-one alternation of ductile and brittle phases.The findings reveal that UVAG reduces fiber damage and surface roughness compared to CG,especially when grinding along FT.UVAG lowers normal(F_(n))and tangential grinding forces(F_(t))by 15.3%and 12.3%,respectively.This highlights UVAG's potential for improving the machinability of complex materials like CFMMCs.The proposed grinding force model closely matches the experimental results.This paper hopes to support the precision abrasive machining of CFMMCs,a kind of complex and highly anisotropic composite material,and promote their application in the fields such as aerospace.展开更多
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co-supported by the Enterprise Innovation and Development Joint Program of the National Natural Science Foundation of China(No.U20B2032)Open Project Funding of State Key Laboratory for High Performance Tools(GXNGJSKL-2024-08)+1 种基金Open Foundation of the State Key Laboratory of Intelligent Manufacturing Equipment and Technology(IMETKF2023005)Introduced Innovative Scientific Research Team Project of Zhongshan(the tenth batch)(CXTD2023008)。
文摘Micro-grinding has been widely used in aerospace and other industry.However,the small diameter of the micro-grinding tool has limited its machining performance and efficiency.In order to solve the above problems,micro-structure has been applied on the micro-grinding tool.A morphology modeling has been established in this study to characterize the surface of microstructured micro-grinding tool,and the grinding performance of micro-structured micro-grinding tool has been analyzed through undeformed chip thickness,abrasive edge width,and effective distance between abrasives.Then deviation analysis,path optimization and parameter optimization of microchannel array precision grinding have been finished to improve processing quality and efficiency,and the deflection angle has the most obvious effects on the rectangular slot depth,micro-structured micro-grinding tool could reduce 10%surface roughness and 20%grinding force compared to original micro-grinding tool.Finally,the microchannel array has been machined with a size deviation of 2μm and surface roughness of 0.2μm.
基金Supported by National Natural Science Foundation of China(Grant Nos.52475480,51805334)Guangdong Basic and Applied Basic Research Foundation(Grant Nos.2023A1515030249,2023A1515110059)Shenzhen Science and Technology Program(Grant No.GJHZ20220913144212023).
文摘SiC-reinforced aluminum matrix(SiCp/Al)composite is widely utilized in the aerospace,automotive,and electronics industries due to the combination of ceramic hardness and metal toughness.However,the significant disparity in properties between SiC particles and the aluminum matrix results in severe tool wear and diminished surface quality during conventional machining.This study proposes an environmentally friendly and clean dry electrical discharge assisted grinding process as an efficient and low-damage machining method for SiCp/Al.An experimental platform was set up to study the impact of grinding and discharge process parameters on surface quality.The study compared the chip formation mechanism and surface quality between dry electrical discharge assisted grinding and conventional grinding,revealing relationships between surface roughness,grinding force,grinding temperature,and related parameters.The results indicate that the proposed grinding method leads to smaller chip sizes,lower grinding forces and temperatures,and an average reduction of 19.2%in surface roughness compared to conventional grinding.The axial,tangential,and normal grinding forces were reduced by roughly 10.5%,37.8%,and 23.0%,respectively.The optimized process parameters were determined to be N=2500 r/min,vf=30 mm/min,a=10μm,E=15 V,f=5000 Hz,dc=80%,resulting in a surface roughness of 0.161μm.
基金financially supported by the National Natural Science Foundation of China(Nos.92160301,92060203,52175415 and 52205475)the Science Center for Gas Turbine Project(Nos.P2022-AB-Ⅳ-002-001 and P2023-B-Ⅳ-003-001)+3 种基金the Jiangsu Key Laboratory of Precision and Micro-Manufacturing Technology(No.JSKL2223K01)the Natural Science Foundation of Jiangsu Province(No.BK20210295)the Superior Postdoctoral Project of Jiangsu Province(No.2022ZB215)the Henan Science and Technology Public Relations Project(No.212102210445).
文摘The undeformed chip thickness and grinding force are key parameters for revealing the material removal mechanism in the grinding process.However,they are difficult to be well expressed due to the ununiformed protrusion height and random position distribution of abrasive grains on the abrasive wheel surface.This study investigated the distribution of undeformed chip thickness and grinding force considering the non-uniform characteristics of abrasive wheel in the grinding of K4002 nickel-based superalloy.First,a novel grinding force model was established through a kinematic-geometric analysis and a grain-workpiece contact analysis.Then,a series of grinding experiments were conducted for verifying the model.The results indicate that the distribution of undeformed chip thickness is highly consistent with the Gaussian distribution formula.The increase in the grinding depth mainly leads to an increase in the average value of Gaussian distribution.On the contrary,the increase in the workpiece infeed speed or the decrease in the grinding speed mainly increases the standard deviation of Gaussian distribution.The average and maximum errors of the grinding force model are 4.9%and 14.6%respectively,indicating that the model is of high predication accuracy.
基金Projects(U22B2084,52275483,52075142)supported by the National Natural Science Foundation of ChinaProject(2023ZY01050)supported by the Ministry of Industry and Information Technology High Quality Development,China。
文摘The gears of new energy vehicles are required to withstand higher rotational speeds and greater loads,which puts forward higher precision essentials for gear manufacturing.However,machining process parameters can cause changes in cutting force/heat,resulting in affecting gear machining precision.Therefore,this paper studies the effect of different process parameters on gear machining precision.A multi-objective optimization model is established for the relationship between process parameters and tooth surface deviations,tooth profile deviations,and tooth lead deviations through the cutting speed,feed rate,and cutting depth of the worm wheel gear grinding machine.The response surface method(RSM)is used for experimental design,and the corresponding experimental results and optimal process parameters are obtained.Subsequently,gray relational analysis-principal component analysis(GRA-PCA),particle swarm optimization(PSO),and genetic algorithm-particle swarm optimization(GA-PSO)methods are used to analyze the experimental results and obtain different optimal process parameters.The results show that optimal process parameters obtained by the GRA-PCA,PSO,and GA-PSO methods improve the gear machining precision.Moreover,the gear machining precision obtained by GA-PSO is superior to other methods.
基金supported financially by the National Natural Science Foundation of China(Grant No.12275047).
文摘In ball milling,the process parameters are decisive in influencing the quality and performance of the final ball-milled product,and crucial but often neglected is the ratio of the grinding balls in terms of their size.Here,for a given number of large grinding balls,the ratio of large to small ones is set to 1:2,1:3,1:4,and 1:5 by altering the number of small ones,and how this affects the morphology,structure,and electrochemical properties of ball-milled graphene nanosheets is investigated.The results show that changing the ball ratio causes distinct changes in the morphology,structure,and properties of the graphene nanosheets.Increasing the number of small(6 mm)grinding balls decreases the nanosheet grain size monotonically;meanwhile,the crystal plane spacing,defect density,and specific surface area increase and then decrease,but the graphitization degree decreases and then increases.Ball-milled samples are then used as anodes for lithium-ion batteries,and both the specific capacity and rate capability exhibit the same trend of increase and then decrease.The ball ratio of 1:3 gives the best electrochemical performance,i.e.,a reversible specific capacity of 262.09 mA·h/g at a current density of 100 mA/g,and even after 2000 cycles at 2000 mA/g,the reversible specific capacity is 87.4%of the optimal value.
基金Project supported by the National Natural Science Foundation of China(51964009)。
文摘Co-associated rare earth elements(lanthanide and yttrium,REY)in coal and its by-products have been considered important potential nontraditional rare earth sources.In this study,a coal gangue sample collected from a coal processing plant in Jinsha County of Guizhou Province,southwest China,was used as the research object.The content,modes of occurrence,and extraction(acid leaching after pretreatment of selective grinding,tailings discarding,and alkali roasting)of REY from the sample were analyzed.The result shows that the content of REY(1038.26μg/g)in pyrite and quartz is low but mainly enriched in kaolinite.Under the following conditions of a filling ratio of 40%(grinding media steel ball)and grinding time of 8 min,selective grinding pretreatment is applied to achieve 176.95μg/g(yield 24.08%)and 1104.93μg/g(yield 75.92%)of REY in+2 mm and-2 mm fractions,respectively.Thus,the-2 mm coal gangue fraction is selected,used as the feed,and roasted and leached with HCl.When Na_(2)CO_(3)and NaCl are separately used as roasting activators,the REY leaching ratios are 91.41%and 68.88%,respectively,under the optimum conditions.The contents of REY in the final leachate are 1010.02 and 761.08μg/g when Na_(2)CO_(3)and NaCl are used,respectively.The two REY contents are relatively higher than the impurity ions in the leachate,which facilitates further REY separation.The mechanism study reveals that high-temperature roasting increases the pore size and the total pore area of the gangue,which promotes leachate penetration and improves reaction efficiency.In addition,roasting facilitates the reaction between the sodium salt activator and kaolinite and other aluminosilicate minerals in the coal gangue to generate soluble salts,thus releasing REY into the solution.The appropriate roasting temperature transforms the activator into a molten state.Thus,the reaction between coal gangue and activator is a solid-liquid reaction rather than a solid-solid reaction,which improves the efficiency of the chemical reaction.
基金supported by the National Natural Science Foundation of China (No. 52075059)Graduate Scientific Research and Innovation Foundation of Chongqing (No. CYB23021)the Innovation Fund of Aero Engine Corporation of China (No. ZZCX-2022-019)。
文摘The machining precision of blades is critical to the service performance of aero engines.The Leading Edge(LE) of high-pressure compressor blades poses a challenge for precision machining due to its thin size, high degree of bending, and significant change of curvature. Aimed at optimizing the machining error, this paper presents a framework that integrates toolpath planning and process parameter regulation. Firstly, an Iterative Subdivision Algorithm(ISA) for clamped Bspline curve is proposed, based on which toolpath planning method towards the LE is developed.Secondly, the removal effect of Cutter Contact(CC) point on the sampling points is investigated in the calculation of grinding dwell time by traversing in u-v space. A global material removal model is constructed for the solution. Thirdly, the previous two steps are interconnected based on the Improved Whale Optimization Algorithm(IWOA), and the optimal parameter combination is searched using the Root Mean Square Error(RMSE) of the machining error as the objective function. Based on this, the off-line programming and robotic grinding experiments are carried out. The experimental results show that the proposed method with error optimization can achieve 0.0143 mm mean value and 0.0160 mm standard deviations of LE surface error, which is an improvement of32.5% and 33.9%, respectively, compared with previous method.
基金supported by the National Key Research and Development Program of China(2022YFB3605902)the National Natural Science Foundation of China(52375411,52293402)。
文摘Workpiece rotational grinding is widely used in the ultra-precision machining of hard and brittle semiconductor materials,including single-crystal silicon,silicon carbide,and gallium arsenide.Surface roughness and subsurface damage depth(SDD)are crucial indicators for evaluating the surface quality of these materials after grinding.Existing prediction models lack general applicability and do not accurately account for the complex material behavior under grinding conditions.This paper introduces novel models for predicting both surface roughness and SDD in hard and brittle semiconductor materials.The surface roughness model uniquely incorporates the material’s elastic recovery properties,revealing the significant impact of these properties on prediction accuracy.The SDD model is distinguished by its analysis of the interactions between abrasive grits and the workpiece,as well as the mechanisms governing stress-induced damage evolution.The surface roughness model and SDD model both establish a stable relationship with the grit depth of cut(GDC).Additionally,we have developed an analytical relationship between the GDC and grinding process parameters.This,in turn,enables the establishment of an analytical framework for predicting surface roughness and SDD based on grinding process parameters,which cannot be achieved by previous models.The models were validated through systematic experiments on three different semiconductor materials,demonstrating excellent agreement with experimental data,with prediction errors of 6.3%for surface roughness and6.9%for SDD.Additionally,this study identifies variations in elastic recovery and material plasticity as critical factors influencing surface roughness and SDD across different materials.These findings significantly advance the accuracy of predictive models and broaden their applicability for grinding hard and brittle semiconductor materials.
基金supported by the National Natural Science Foundation of China(Grant Nos.52375420,52322510)Natural Science Foundation of Heilongjiang Province of China(Grant No.YQ2023E014)+6 种基金National Key Research and Development Program of China(Grant No.2021YFB3400403)Shenzhen Science and Technology Program(Grant No.GNCWSSJH20240032)Self-Planned Task(Grant No.SKLRS202214B)of State Key Laboratory of Robotics and System(HIT),China Postdoctoral Science Foundation(Grant No.2022T150163)Young Elite Scientists Sponsorship Program by CAST(Grant No.YESS20220463)Open Fund of Key Laboratory of Microsystems and Microstructures Manufacturing(HIT)(Grant No.2022KM004)Open Foundation of Hunan Provincial Key Laboratory of High Efficiency and Precision Machining of Difficult-to-Cut Material(Grant No.E22445)Fundamental Research Funds for the Central Universities(Grant Nos.HIT.OCEF.2022024,FRFCU5710051122)。
文摘Silicon carbide(SiC)ceramics are extensively utilized in aerospace,national defense,and petrochemical industries due to their superior physical and chemical properties.The processing of bulk SiC ceramics necessitates precise and efficient grinding techniques to produce components with satisfactory functionality.However,the inherent high hardness and brittleness of SiC ceramics present significant challenges during grinding,leading to severe brittle fracture and tool wear that compromise both surface integrity and production efficiency.Although ductile-regime grinding of SiC ceramics can be achieved by enhancing machine tool accuracy and stiffness while optimizing wheel performance alongside appropriate selection of process parameters,a comprehensive summary of the mechanisms underlying damage evolution during grinding is lacking,and a mature grinding process for SiC ceramics has yet to be developed.To bridge this gap,the sintering technologies,mechanical properties,and microstructures of SiC ceramics were briefly covered.The grinding-induced damage mechanism and low-damage grinding technologies of SiC ceramics were summarized.The fundamental science underlying the ductile deformation and removal mechanisms of brittle solids was emphasized.Additionally,attention was directed towards the critical role of hybrid energy field grinding in minimizing brittle damages and promoting removal efficiency.This review not only elucidates the intrinsic interactions between the work material and abrasives,but also offers valuable insights for optimizing the grinding processes of brittle solids.
基金financially supported by the Key Research and Development Program of Hubei Province(Nos.2022BCA077 and 2022BCA082).
文摘Styrene-butadiene-styrene(SBS)modified asphalt(SA)has long found effective applications in road construction materials.When combined with fillers,SBS-modified asphalt has demonstrated promising resistance to fatigue cracking caused by temperature fluctuations and aging.In this study,molybdenum disulfide(MoS_(2))and polyphosphoric acid(PPA)were ground in naphthenic oil(NO)and subjected to mechanical activation to create PPAmodified MoS_(2),referred to as OMS-PPA.By blending various ratios of OMS-PPA with SBS-modified asphalt,composite-modified asphalts were successfully developed to enhance their overall properties.To assess the mechanical characteristics and stability of these modified asphalts,various methods were employed,including penetration factor,flow activation energy,fluorescence microscopy,and dynamic shear rheology.Additionally,the short-term aging performance was evaluated using Fourier transform infrared(FTIR)spectroscopy and nanoindentation tests.The results revealed a 3.7%decrease in the penetration-temperature coefficient for SAOMS compared to SA,while 1-SA-OMS-PPA showed an even greater reduction of 7.1%.Furthermore,after short-term aging,carboxyl group generation in SA increased by 5.93%,while SA-OMS exhibited a smaller rise of 1.36%,and 1-SA-OMS-PPA saw an increase of just 0.93%.The study also highlighted significant improvements in the hardness of these materials.The hardness change ratio for SA-OMS decreased by 43.08%,while the ratio for 1-SA-OMS-PPA saw a notable reduction of 65.16% compared to unmodified SA.These findings suggest that OMS-PPA contributed to improvements in temperature sensitivity,particle dispersibility,and resistance to shortterm aging in asphalts.The results hold significant promise for the future development of advanced asphalt-based materials with potential high-value applications in flexible pavements for highways.
基金supported by the Na-tional Natural Science Foundation of China(No.51675457)the Jiangsu Key Laboratory of Precision and Micro-man-ufacturing Technology.
文摘Sapphire hemispherical domes are machined through milling and shaping using brazed diamond tools.A mathematical model describing roughness for this processing method is established,and the relationship between roughness and its influencing factors is analyzed.Experiments on the hemispherical dome shaping process are conducted to validate the model,analyzing the variation in roughness under different tool and workpiece rotational speeds.The results are consistent with the predictions of the established roughness model,suggesting that the model can be used to guide subsequent process experiments.Milling and shaping efficiency using brazed diamond tools typically can reach 14 g/min.The machined sapphire surfaces exhibit relatively few microcracks and minimal damage,with almost all exclusively visible grooves resulting from brittle fracture removal.The surface roughness after machining is below 2.5μm.Milling sapphire domes with brazed diamond tools represents a novel shaping technique characterized by high efficiency and high quality.
基金financially supported by the General Program of National Natural Science Foundation of China(No.52174330)Hunan Provincial Innovation Foundation for Postgraduate(No.QL20220069)Postgraduate Innovative Project of Central South University(No.1053320214756).
文摘The utilization of ironsand for preparing oxidized pellets poses challenges,including slow oxidation and low consolidation strength.The effects and function mechanisms of high-pressure grinding roll(HPGR)pretreatment on the oxidation and consolidation of ironsand pellets were investigated,and the energy utilization efficiency of HPGR with different roller pressure intensities was evaluated.The results indicate that HPGR pretreatment at 8 MPa improves the ironsand properties,with the specific surface area increasing by 740 cm^(2) g^(-1) and mechanical energy storage increasing by 2.5 kJ mol^(-1),which is conducive to oxidation and crystalline connection of particles.As roller pressure intensity increases to 16 MPa,more mechanical energy of HPGR is applied for crystal activation,with mechanical energy storage further rising by 18.1 kJ mol^(-1).The apparent activation energy for pellet oxidation initially decreases and then increases,reaching a minimum at 12 MPa.Simultaneously,the roasted pellets porosity decreases by 2.8%,while the compressive strength increases by 789 N.At higher roller pressure intensity,the densely connected structure between particles impedes gas diffusion within the pellets,diminishing the beneficial effects of HPGR on pellet oxidation.Moreover,excessive roller pressure intensity decreases the HPGR energy utilization efficiency.The optimal HPGR roller pressure intensity for ironsand is 12 MPa,at which the specific surface area increases by 790 cm^(2) g^(-1),mechanical energy storage increases by 10.6 kJ mol^(-1),the compressive strength of roasted pellets rises to 2816 N,and the appropriate preheating and roasting temperatures decrease by 250 and 125°C,respectively.
基金Supported by National Natural Science Foundation of China(Grant No.52175401)Hunan Provincial Postgraduate Scientific Research Innovation Project(Grant No.QL20230244)+1 种基金Enterprise Innovation and Development Joint Program of National Natural Science Foundation of China(Grant No.U20B2032)Hunan Provincial Science and Technology Innovation Program(Grant No.2022RC1050).
文摘Because the grinding temperature is high when grinding using conventional disordered grinding wheels,the grinding quality improvement is limited when using single abrasive ordered grinding wheels,and the wheel preparation process is complex and costly when using microstructured grinding wheels,abrasive groups ordered grinding wheels are widely investigated.However,there is a paucity of systematic analyses and comprehensive reviews focused on abrasive groups ordered grinding wheels.Therefore,this paper defines abrasive groups ordered grinding wheels and classifies them,based on their unique characteristics,into groups such as abrasive blocks ordered grinding wheel,fine grain structured grinding wheel,abrasive clusters ordered grinding wheel,and abrasive fibers ordered grinding wheel.We provide an overview of the latest advances in wheel structures,preparation methods,and abrasive selection for various types of abrasive groups ordered grinding wheels.Furthermore,we conduct a comparative analysis of the existing types,significant advantages,and challenges associated with the four types of abrasive groups ordered grinding wheels.Looking ahead,given the potential of abrasive groups ordered grinding wheels in reducing grinding force and temperature,we recommend further exploration of their application in combination with special processing techniques.This could pave the way for the development of machining processes that are more environmentally friendly,energy-efficient,and precise.
基金Supported by Fundamental Research Funds for the Central Universities(Grant No.2019JBM050).
文摘This research aimed to overcome challenges such as high costs,lengthy optimization time,and low efficiency in resolving issues related to wheel-rail contact,rail wear,and vehicle dynamics.Based on the wheel-rail contact parameters,an optimal design method for rail grinding target profile is proposed from wear profile measurement to grinding profile design according to the actual railway track and vehicle operating conditions.We utilized Isight to create a simulation test and developed an RBF proxy model that incorporated both mechanical and geometric aspects of wheel-rail contact.By integrating rail modeling,wheel-rail contact analysis,and multi-objective optimization,we established a rail grinding optimization model that was solved using the NSGA-II algorithm.After optimization,the study achieved a 31.863%reduction in average contact stress,a 70.5%reduction in matching wear work,and a 100.391%increase in the difference in rolling radius between the wheel and rail.
基金Supported by National Key Research and Development Program of China(Grant No.2023YFB3711100)National Natural Science Foundation of China(Grant Nos.52275458,52275207)Tianjin Municipal Natural Science Foundation(Grant No.22JCZDJC00050)。
文摘Any product must undergo precise manufacturing before use.The damage incurred during the manufacturing process can significantly impact the residual strength of the product post-manufacturing.However,the relationship between residual bending strength and manufacturing-induced damage remains unclear,despite being a crucial parameter for assessing material service life and performance,leading to a decrease in product performance reliability.This study focuses on investigating the impact of crack generation on residual bending strength through theoretical and experimental analyses of scratching,grinding,and three-point bending.The research first elucidates the forms and mechanisms of material damage through scratch experiments.Subsequently,using resin-bonded and electroplated wheels as case studies,the influence of different process parameters on grinding damage and residual bending strength is explored.The reduction of brittle removal can lead to a 50%–60%decrease in residual bending strength.Lastly,a model is developed to delineate the relationship between processing parameters and the residual bending strength of the product,with the model exhibiting an error margin of less than 11%.This model clearly reveals the effect of crack generation under different process parameters on residual flexural strength.
基金the Central Guidance on Local Science and Technology Development Fund of Hubei Province(No.2022BFE002)the Independent Innovation Projects of the Hubei Longzhong Laboratory(No.2022ZZ-06)the National Natural Science Foundation of China(Nos.52002075 and 62204179)。
文摘Compared with sintered silicon carbides(SiC),highly-orientated 3C-SiC by CVD methods boast out-of-plane orientation uniformity,which ensures that such materials produce lower surface damage.Through the electrolytic in-process dressing(ELID)grinding technique,the differences in grinding behaviors between<110>and<111>-orientated 3C-SiC were investigated.Both highly-orientated 3C-SiC exhibited a grinding surface where brittle and ductile removal coexisted.Specifically,brittle removal regions were observed at grain boundaries,while ductile removal regions were observed within the grains.Further indentation experiments between the two 3C-SiC show that<111>-oriented 3C-SiC displays a larger critical cut depth of 28.99 nm,with 1.5 times higher than that of<110>-oriented 3C-SiC.The larger critical depth of cut contributes to more ductile removal regions with only a few brittle pits in the<111>-oriented 3C-SiC grinding surface.In addition,the subsurface deformation of<110>-oriented 3C-SiC was characterized by the presence of amorphous zones,dislocations and stacking faults.In contrast to the<111>-oriented,the<110>-oriented 3C-SiC tends to exhibit a brittle removal mode dominated by pits and cracks at the twin boundaries,as its pre-existing twins hinder the dislocation glide,resulting in stress concentration and thus forming cracks.
基金supported by the National Natural Science Foundation of China(Nos.92160301,92060203,52175415,52205475,and 52322510)the Science Center for Gas Turbine Project(No.P2023-B-IV-003-001)+1 种基金the Huaqiao University Engineering Research Center of Brittle Materials Machining(No.2023IME-001)the Natural Science Foundation of Jiangsu Province(No.BK20210295).
文摘Machined surface integrity of workpieces in harsh environments has a remarkable influence on their performance.However,the complexity of the new type of machining hinders a comprehensive understanding of machined surface integrity and its formation mechanism,thereby limiting the study of component performance.With increasing demands for high-quality machined workpieces in aerospace industry applications,researchers from academia and industry are increasingly focusing on post-machining surface characterization.The profile grinding test was conducted on a novel single-crystal superalloy to simulate the formation of blade tenons,and the obtained tenons were characterized for surface integrity elements under various operating conditions.Results revealed that ultrasonic vibration-assisted grinding(UVAG)led to multiple superpositions of abrasive grain trajectories,causing reduced surface roughness(an average reduction of approximately29.6%)compared with conventional grinding.After examining the subsurface layer of UVAG using transmission electron microscopy,the results revealed that the single-crystal tenon grinding subsurface layer exhibited a gradient evolution from the near-surface to the substrate.This evolution was characterized by an equiaxed nanocrystalline layer measuring 0.34μm,followed by a submicrocrystalline grain-forming zone spanning 0.6μm and finally,a constituent phase-twisted dis-torted deformation zone over 0.62μm.Under normal grinding conditions,the tenon exhibited low surface hardening(not exceeding 15%),and residual compressive stresses were observed on its surface.In cases where grinding burns occurred,a white layer appeared on the tenon's surface,which demonstrated varying thicknesses along the teeth from top to root due to thermal-force-structural coupling effects.Additionally,these burns introduced residual tensile stresses on the tenon's surface,potentially substantially affecting its fatigue life.This paper enhances our understanding of UVAG processes and establishes a foundation for their application in manufacturing singlecrystal turbine blades for next-generation aero-turbine engines.
基金the support of the National Natural Science Foundation of China(Nos.52205476 and 52175415)the Natural Science Foundation of Jiangsu Province(No.BK20242040)+1 种基金the Fundamental Research Funds for the Central Universities(No.NG2024008)the Fund of Jiangsu Key Laboratory of Precision and Micro-Manufacturing Technology(No.1005ZAA20003-14)。
文摘The manufacturing industry is the core support for the development of the real economy.While promoting rapid economic growth,it also brings severe resource and environmental challenges.China's manufacturing industry has ranked first in the world in terms of energy consumption,accounting for 56%of China's total energy consumption.Its electricity consumption exceeds 50%of the total social electricity consumption,and its carbon emissions reach 1.81 billion tons,accounting for 34% of the national total.Against this backdrop,enhancing the sustainability of high-end equipment manufacturing industries represented by aerospace has become a major strategic need for China's modernization,and it also provides strong support for solving global environmental problems.
基金financially supported by the National Natural Science Foundation of China(Nos.92160301,52175415,and 52205475)the Science Center for Gas Turbine Project(No.P2023-B-Ⅳ-003-001)+2 种基金the Natural Science Foundation of Jiangsu Province(No.BK20210295)the Fundamental Research Funds for the Central Universities(Nos.NG2024015 and NS2023028)the State Key Laboratory of Mechanics and Control for Aerospace Structures(Nanjing University of Aeronautics and Astronautics)(No.MCAS-S-0423G02)。
文摘Continuous Fiber-reinforced Metal Matrix Composites(CFMMCs),such as Si C fiberreinforced TC17 matrix composites(SiC_(f)/TC17),are renowned for their exceptional mechanical properties.However,their heterogeneous compositions present significant machining challenges,including fiber pullout,matrix cracking,and accelerated tool wear.Ultrasonic Vibration-Assisted Grinding(UVAG)has proven to be an effective technique for overcoming these challenges.The material removal mechanisms in UVAG,especially in composites with both ductile and brittle phases,remain poorly understood.To explore these issues,UVAG and Conventional Grinding(CG)experiments were conducted on SiC_(f)/TC17 along two grinding directions:fiber's transverse direction(FT)and fiber's longitudinal direction(FL).This paper aims to provide a new dynamic mechanical model and shed light on the complex removal mechanisms in CFMMCs,which are characterized by a near one-to-one alternation of ductile and brittle phases.The findings reveal that UVAG reduces fiber damage and surface roughness compared to CG,especially when grinding along FT.UVAG lowers normal(F_(n))and tangential grinding forces(F_(t))by 15.3%and 12.3%,respectively.This highlights UVAG's potential for improving the machinability of complex materials like CFMMCs.The proposed grinding force model closely matches the experimental results.This paper hopes to support the precision abrasive machining of CFMMCs,a kind of complex and highly anisotropic composite material,and promote their application in the fields such as aerospace.
