The remarkable ability of titanium alloys to preserve their superior physical and chemical characteristics when subjected to extreme conditions significantly enhances their importance in the aerospace,military,and med...The remarkable ability of titanium alloys to preserve their superior physical and chemical characteristics when subjected to extreme conditions significantly enhances their importance in the aerospace,military,and medical sectors.However,conventional machining of titanium alloys leads to elevated tool wear,development of surface defects,and reduced machining efficiency due to their low heat conductivity,and chemical affinity.These issues can be somewhat counteracted by integrating ultrasonic vibration in the conventional machining of titanium alloys and also enhance sustainability.This review article offers a holistic evaluation of the influence of ultrasonic vibration-assisted milling and turning on cutting forces,temperature,tool wear,and surface integrity,encompassing surface morphology,surface roughness,surface residual stress,surface hardness,and surface tribological properties during titanium alloys machining.Furthermore,it investigates the sustainability aspect that has not been previously examined.Studies on the performance of ultrasonic-assisted cutting revealed several advantages,including decreased cutting forces and cutting temperature,improved tool life,and a better-machined surface during machining.Consequently,the sustainability factor is improved due to minimized energy consumption and residual waste.In conclusion,the key challenges and future prospects in the ultrasonic-assisted cutting of titanium alloys are also discussed.This review article provides beneficial knowledge for manufactur-ers and researchers regarding ultrasonic vibration-assisted cutting of titanium alloy and will play an important role in achieving sustainability in the industry.展开更多
Glass,with its valuable properties,finds extensive use in aerospace,optics,and biomedical fields.Owing to its low fracture toughness,glass typically fractures in a brittle manner during machining,resulting in poor sur...Glass,with its valuable properties,finds extensive use in aerospace,optics,and biomedical fields.Owing to its low fracture toughness,glass typically fractures in a brittle manner during machining,resulting in poor surface quality.This paper presents an experimental investigation of vibration-assisted machining(VAM)techniques to enhance the machining of glass materials.A novel high-frequency two-dimensional VAM system specifically designed for glass is introduced,and slot milling experiments are conducted using ultrasonic high-frequency vibrations.A low-frequency nonresonant VAM system is also employed for comparison purposes.A comprehensive examination is made of the effects of various machining parameters,such as feed rate,cutting speeds,and vibration parameters,including vibration modes and amplitudes,on the machining performance of glass.Surface roughness,edge chipping generation,and tool wear are thoroughly characterized using scanning electron microscopy.The findings demonstrate that under specific machining and vibration parameters,the proposed ultrasonic vibration-assisted micro-milling(UVAMM)system can achieve a nanometric surface roughness Ra for glass.The UVAMM system offers enhanced surface quality,improved edge quality,and reduced tool wear compared with conventional machining techniques.This study provides valuable insights and directions for the application of 2D VAM systems in achieving superior machining results for glass components at small scales with nanometric surface finishes.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
Micro/nano hierarchical structures could endow materials with various surface functions.However,the multilayer and multiscale characteristics of micro/nano hierarchical structures bring difficulties for their one step...Micro/nano hierarchical structures could endow materials with various surface functions.However,the multilayer and multiscale characteristics of micro/nano hierarchical structures bring difficulties for their one step and controllable fabrication.Accordingly,based on tip-based fabrication techniques,this study proposed a micro-amplitude vibration-assisted scratching method by introducing a periodic backward displacement into the conventional scratching process,which enabled the synchronous creation of the microscale V-groove and nanoscale ripples,i.e.a typical micro/nano hierarchical structure.The experiments and finite element modeling were employed to explore the formation process and mechanism of the micro/nano hierarchical structures.Being different from conventional cutting,this method was mainly based on the plow mechanism,and it could accurately replicate the shape of the indenter on the material surface.The microscale V-groove was formed due to the scratching action,and the nanoscale ripple was formed due to the extrusion action of the indenter on the microscale V-groove’s surface.Furthermore,the relationships between the processing parameters and the dimensions of the micro/nano hierarchical structures were established through experiments,and optimized processing parameters were determined to achieve regular micro/nano hierarchical structures.By this method,complex patterns constructed by various micro/nano hierarchical structures were fabricated on both flat and curved surfaces,achieving diverse surface structural colors.展开更多
Gamma titanium-aluminum intermetallic compounds(γ-TiAl)have gained considerable attentions in the aerospace industry due to their exceptional thermal resilience and comprehensive attributes,making them a prime exampl...Gamma titanium-aluminum intermetallic compounds(γ-TiAl)have gained considerable attentions in the aerospace industry due to their exceptional thermal resilience and comprehensive attributes,making them a prime example of lightweight and advanced materials.To address the frequent occurrence of burns and severe tool deterioration during the process of high-efficiency deep grinding(HEDG)onγ-TiAl alloys,ultrasonic vibration-assisted high-efficiency deep grinding(UVHEDG)has been emerged.Results indicate that in UVHEDG,the grinding temperature is on average 15.4%lower than HEDG due to the employment of ultrasonic vibrations,enhancing coolant penetration into the grinding area and thus reducing heat generation.Besides,UVHEDG possesses superior performance in terms of grinding forces compared to HEDG.As the material removal volume(MRV)increases,the tangential grinding force(F_(t))and normal grinding force(F_(n))of UVHEDG increase but to a lesser extent than in HEDG,with an average reduction of16.25%and 14.7%,respectively.UVHEDG primarily experiences microfracture of grains,whereas HEDG undergoes large-scale wear later in the process due to increased grinding forces.The surface roughness(R_(a))characteristics of UVHEDG are superior,with the average value of R_(a)decreasing by 46.5%compared to HEDG as MRV increases.The surface morphology in UVHEDG exhibits enhanced smoothness and a shallower layer of plastic deformation.Grinding chips generated by UVHEDG show a more shear-like shape,with the applied influence of ultrasonic vibration on chip morphology,thereby impacting material removal behaviors.These aforementioned findings contribute to enhanced machining efficiency and product quality ofγ-TiAl alloys after employing ultrasonic vibrations into HEDG.展开更多
Textured surfaces with certain micro/nano structures have been proven to possess some advanced functions,such as reducing friction,improving wear and increasing wettability.Accurate prediction of micro/nano surface te...Textured surfaces with certain micro/nano structures have been proven to possess some advanced functions,such as reducing friction,improving wear and increasing wettability.Accurate prediction of micro/nano surface textures is of great significance for the design,fabrication and application of functional textured surfaces.In this paper,based on the kinematic analysis of cutter teeth,the discretization of ultrasonic machining process,transformation method of coordinate systems and the cubic spline data interpolation,an integrated theoretical model was established to characterize the distribution and geometric features of micro textures on the surfaces machined by different types of ultrasonic vibration-assisted milling(UVAM).Based on the theoretical model,the effect of key process parameters(vibration directions,vibration dimensions,cutting parameters and vibration parameters)on tool trajectories and microtextured surface morphology in UVAM is investigated.Besides,the effect of phase difference on the elliptical shape in 2D/3D ultrasonic elliptical vibration-assisted milling(UEVAM)was analyzed.Compared to conventional numerical models,the method of the cubic spline data interpolation is applied to the simulation of microtextured surface morphology in UVAM,which is more suitable for characterizing the morphological features of microtextured surfaces than traditional methods due to the presence of numerous micro textures.The prediction of surface roughness indicates that the magnitude of ultrasonic amplitude in z-direction should be strictly limited in 1D rotary UVAM,2D and 3D UEVAM due to the unfavorable effect of axial ultrasonic vibration on the surface quality.This study can provide theoretical guidance for the design and fabrication of microtextured surfaces in UVAM.展开更多
C_(f)/SiC composites are characterized as anisotropic,heterogeneous,brittle,and hard materials.The process of manufacturing C_(f)/SiC composites using traditional machining techniques is prone to edge chipping damage ...C_(f)/SiC composites are characterized as anisotropic,heterogeneous,brittle,and hard materials.The process of manufacturing C_(f)/SiC composites using traditional machining techniques is prone to edge chipping damage and tool wear,which makes it difficult to meet the machining quality and machining accuracy.The purpose of this paper is to investigate the milling characteristics and damage assessment during ultrasonic vibration-assisted end milling(UVAEM)of C_(f)/SiC composites.Firstly,UVAEM experiments on C_(f)/SiC composites were carried out at different ultrasonic amplitudes and comparative experiments with conventional milling(CM).In addition,tool wear,surface roughness,surface micromorphology,milling force and subsurface damage(SSD)were measured and analysed.Finally,the SSD factors of C_(f)/SiC composites were established to quantify machining damage,and analyzed the effect of ultrasonic amplitude on SSD.Furthermore,the formation mechanism of SSD was investigated and discussed.The findings indicate that appropriate ultrasonic amplitude improves the surface quality by UVAEM,while excessive amplitude deteriorates the surface quality.During the UVAEM,micro/macro brittle fracture of the fibers on the surface occurs,leading to machining defects such as fiber breakage,fiber-interface debonding and pits.The milling force gradually decreases with the increase of ultrasonic amplitude.On the other hand,the forms of SSD in CM and UVAEM are mainly fiber pullout,subsurface crack,crack extension and machining pits.Matrix cracking and fiber pullout in SSD were affected by fiber orientation.Moreover,the introduction of ultrasonic vibration plays a significant contribution in the inhibition of the SSD in C_(f)/SiC composites.展开更多
Ultrasonic vibration-assisted ELID(UVA-ELID)grinding is utilized as a novel and highly efficient processing method for hard and brittle materials such as ceramics.In this study,the UVA-ELID grinding ZTA ceramics is em...Ultrasonic vibration-assisted ELID(UVA-ELID)grinding is utilized as a novel and highly efficient processing method for hard and brittle materials such as ceramics.In this study,the UVA-ELID grinding ZTA ceramics is employed to investigate the influence of thermomechanical loading on the characteristics of oxide film.Based on the fracture mechanics of material,the model of internal stress for oxide film damage is proposed.The thermomechanical loading is composed of mechanical force and the thermal stress generating from grinding temperature.The theoretical model is established for the mechanical force,thermal stress and internal stress respectively.Then the finite element analysis method is used to simulate the theoretical model.The mechanical force and grinding temperature is measured during the actual grinding test.During the grinding process,the effect of grinding wheel speed and grinding depth on the thermomechanical force and the characteristics of oxide film is analyzed.Compared with the conventional ELID(CELID)grinding,the mechanical force decreased by 25.6%and 22.4%with the increase of grinding wheel speed and grinding depth respectively,and the grinding temperature declined by 10.7%and12.8%during the UVA-ELID grinding.The thermal stress in the latter decreased by 16.3%and20.8%respectively,and internal stress reduced by 12.3%and 15.6%.It was experimentally found that the topographies of oxide layer on the surface of the wheel and the machined surface in the latter was better than that in the former.The results indicate that the action of ultrasonic vibration establish a significant effect on the processing.Subsequently,it should be well considered for future reference when processing the ZTA ceramics.展开更多
The ultrafast laser based hybrid machining system was studied and a novel approach was demonstrated to improve laser machining quality on metals by vibrating the optical objective lens with a low frequency (500 Hz) an...The ultrafast laser based hybrid machining system was studied and a novel approach was demonstrated to improve laser machining quality on metals by vibrating the optical objective lens with a low frequency (500 Hz) and various displacements (0-16.5 μm) during a femtosecond laser machining process.The laser used in this experiment is an amplified Ti:sapphire femtosecond (10-15 s) laser system that generates 100 femtosecond pulses having an energy of 3.5 mJ/pulse with a 5 kHz repetition rate at a central wavelength of 790 nm.It is found that both the wall surface finish of the machined structures and the aspect ratio obtained using the frequency vibration assisted laser machining are improved compared with those derived via laser machining without vibration assistance.展开更多
Ultrasonic vibration-assisted technology is widely utilized in the performance research and manufacturing process of metallic materials owing to its advantages of introducing highfrequency acoustic systems. However, t...Ultrasonic vibration-assisted technology is widely utilized in the performance research and manufacturing process of metallic materials owing to its advantages of introducing highfrequency acoustic systems. However, the acoustic plasticity constitutive model and potential mechanism, involving Ti3Al intermetallic compounds, have not yet been clarified. Therefore, the Ultrasonic-K-M hybrid acoustic constitutive model of Ti3Al was established by considering the stress superposition, acoustic thermal softening, acoustic softening and acoustic residual hardening effects according to the dislocation density evolution theory and crystal plasticity theory. Meanwhile, the mechanical behavior of ultrasonic vibration-assisted tension(UVAT) and microstructure of ultrasonic vibration-assisted milling(UVAM) for Ti3Al was investigated. Dislocation density to be overcome from initial deformation to failure of Ti3Al was calculated in UVAT and was verified in UVAM. The results indicated that the Ultrasonic-K-M model showed a good agreement with the experimental data. There was an obviously softening phenomenon after introducing the ultrasonic energy field in the Ti3Al whole deformation region, and the degree of softening was positively correlated with amplitude. Furthermore, the maximum reduction ratio in yield strength of Ti3Al was16 % and the maximum reduction value in ultimate tensile strength was 206.91 MPa. The elongation rose first and then fell as amplitude enlarged, but only as the vibration was applied in the whole deformation region, the elongation was always greater than 14.58 %. In addition, The UVAM process significantly reduced the dislocation density increment to be overcome for Ti3Al material removal by 1.37 times, and promoted dislocation motion and cancellation to make twisted dislocations evolve into parallel dislocations. As the amplitude increased to 4 μm, the depth of the disturbed area of the plastic deformation layer increased by a maximum of 2.5 times.展开更多
In this paper,a novel,separable two-degrees-of-freedom stage with high-precision motion and resolution is proposed for the application of vibration-assisted micromilling.A separable design was realized on the basis of...In this paper,a novel,separable two-degrees-of-freedom stage with high-precision motion and resolution is proposed for the application of vibration-assisted micromilling.A separable design was realized on the basis of the detachable structure of the platform.Flexible stages with different dimensions and types can be utilized in the devices.A circular-fillet hinge is selected as the flexible unit with a parallel structure to realize output decoupling and reduce the coupling error between the two vibration directions.Analytical modeling is conducted to explore the static and dynamic characteristics of the stage.Results reveal a good agreement with the finite element simulation result.A series of experiments were conducted to assess the static and dynamic performances of the flexible stage,encompassing tests such as amplitude response,motion trajectory,and coupling trajectory.The results of these tests revealed that the designed vibration-assisted system exhibits precise movement capabilities.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
Ultrasonic vibration-assisted grinding(UVAG)is an effective and promising method for machining of hard-to-cut materials.This article proposed an ultrasonic vibration plate device enabling the longitudinal full-wave an...Ultrasonic vibration-assisted grinding(UVAG)is an effective and promising method for machining of hard-to-cut materials.This article proposed an ultrasonic vibration plate device enabling the longitudinal full-wave and transverse half-wave(L2T1)vibration mode for UVAG.The characteristics of two-dimensional coupled vibration in different directions were analyzed on the basis of apparent elastic method and finite element method.Furthermore,a correction factor was applied to correct the frequency error caused by the apparent elastic method.Finally,the comparative experiments between the conventional creep-feed grinding and UVAG of Inconel 718 nickel-based superalloy were carried out.The results indicate that the apparent elastic method with the correction factor is accurate for the design of plate device under the L2T1 vibration mode.Compared with the conventional creep-feed grinding,the UVAG causes the reduction of grinding force and the improvement of machined surface quality of Inconel 718 nickel-based superalloy.Furthermore,under the current experimental conditions,the optimal ultrasonic vibration amplitude is determined as 6μm,with which the minimum surface roughness is achieved.展开更多
This paper outlines the results of experimental study of the dynamic rock failure based on the comparison of dry and saturated limestone samples obtained during the dynamic compression and split tests. The tests were ...This paper outlines the results of experimental study of the dynamic rock failure based on the comparison of dry and saturated limestone samples obtained during the dynamic compression and split tests. The tests were performed using the Kolsky method and its modifications for dynamic splitting. The mechanical data(e.g. strength, time and energy characteristics) of this material at high strain rates are obtained. It is shown that these characteristics are sensitive to the strain rate. A unified interpretation of these rate effects, based on the structuraletemporal approach, is hereby presented. It is demonstrated that the temporal dependence of the dynamic compressive and split tensile strengths of dry and saturated limestone samples can be predicted by the incubation time criterion. Previously discovered possibilities to optimize(minimize) the energy input for the failure process is discussed in connection with industrial rock failure processes. It is shown that the optimal energy input value associated with critical load, which is required to initialize failure in the rock media, strongly depends on the incubation time and the impact duration. The optimal load shapes, which minimize the momentum for a single failure impact, are demonstrated. Through this investigation, a possible approach to reduce the specific energy required for rock cutting by means of high-frequency vibrations is also discussed.展开更多
Continuous fiber-reinforced metal matrix composites(CFMMCs),reinforced by ceramic fibers(e.g.,Al_(2)O_(3)and SiC fibers)in a tough metal matrix,are extensively utilized in aerospace applications,such as engine casings...Continuous fiber-reinforced metal matrix composites(CFMMCs),reinforced by ceramic fibers(e.g.,Al_(2)O_(3)and SiC fibers)in a tough metal matrix,are extensively utilized in aerospace applications,such as engine casings and piston rods,because of their excellent high-temperature resistance and creep resistance.However,their heterogeneous composition presents machining challenges,including fiber pull-out,matrix adhesion,and increased tool wear.Ultrasonic vibration-assisted grinding(UVAG)effectively reduces grinding forces and abrasive wear.However,research on abrasive machining of specific CFMMCs is lacking.This study conducted single-grain cubic boron nitride grinding on SiC_(f)/TC17 with UVAG and compared the material removal mechanisms along two different directions(longitudinal fiber[LF]and transverse fiber[TF]).A simulation model was proposed to reveal the stress distribution and its propagation.Results showed that UVAG could effectively reduce grinding forces along both directions,with an average reduction of about 17.8%compared with conventional grinding.SiC fibers were removed in three models:micro-fractures,macro-fractures,and pull-outs.The introduction of ultrasonic energy mitigated fiber damage.The simulation model was consistent with Removal Model 1.The matrix’s surface stress during grinding along LF was more concentrated than that during grinding along TF under the action of the abrasive grain.The proposed model helps understand the removal behavior of CFMMCs.This research is expected to enhance the comprehension of abrasive machining of CFMMCs and facilitate their application in the aerospace field.展开更多
Textured surfaces have been widely applied in many fields due to their excellent functional performances.Although several micro-scale surface texturing techniques have been used to fabricate surface textures,most are ...Textured surfaces have been widely applied in many fields due to their excellent functional performances.Although several micro-scale surface texturing techniques have been used to fabricate surface textures,most are either very expensive,have material limitations,or lack flexibility.In this study,a novel textured surface generation method using vibration-assisted ball-end milling with a non-resonant vibrator is proposed.Firstly,the configuration of the vibration-assisted ball-end milling system is introduced.Then,the trajectories of the cutting edges are modeled and analyzed.Furthermore,an analysis of a non-resonant vibrator is conducted.Finally,surface texture machining experiments are conducted,and the feasibility of the proposed vibration-assisted ball-end milling method for surface texture fabrication is verified.展开更多
Ultrasonic vibration-assisted grinding(UVAG)is an advanced hybrid process for the precision machining of difficult-to-cut materials.The resonator is a critical part of the UVAG system.Its performance considerably infl...Ultrasonic vibration-assisted grinding(UVAG)is an advanced hybrid process for the precision machining of difficult-to-cut materials.The resonator is a critical part of the UVAG system.Its performance considerably influences the vibration amplitude and resonant frequency.In this work,a novel perforated ultrasonic vibration platform resonator was developed for UVAG.The holes were evenly arranged at the top and side surfaces of the vibration platform to improve the vibration characteristics.A modified apparent elasticity method(AEM)was proposed to reveal the influence of holes on the vibration mode.The performance of the vibration platform was evaluated by the vibration tests and UVAG experiments of particulate-reinforced titanium matrix composites.Results indicate that the reasonable distribution of holes helps improve the resonant frequency and vibration mode.The modified AEM,the finite element method,and the vibration tests show a high degree of consistency for developing the perforated ultrasonic vibration platform with a maximum frequency error of 3%.The employment of ultrasonic vibration reduces the grinding force by 36%at most,thereby decreasing the machined surface defects,such as voids,cracks,and burnout.展开更多
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(No.P2023-B-IV-003-001)+1 种基金the Natural Science Foundation of Jiangsu Province(No.BK20210295)the Huaqiao University Engineering Research Center of Brittle Materials Machining(MOE,2023IME-001)。
文摘The remarkable ability of titanium alloys to preserve their superior physical and chemical characteristics when subjected to extreme conditions significantly enhances their importance in the aerospace,military,and medical sectors.However,conventional machining of titanium alloys leads to elevated tool wear,development of surface defects,and reduced machining efficiency due to their low heat conductivity,and chemical affinity.These issues can be somewhat counteracted by integrating ultrasonic vibration in the conventional machining of titanium alloys and also enhance sustainability.This review article offers a holistic evaluation of the influence of ultrasonic vibration-assisted milling and turning on cutting forces,temperature,tool wear,and surface integrity,encompassing surface morphology,surface roughness,surface residual stress,surface hardness,and surface tribological properties during titanium alloys machining.Furthermore,it investigates the sustainability aspect that has not been previously examined.Studies on the performance of ultrasonic-assisted cutting revealed several advantages,including decreased cutting forces and cutting temperature,improved tool life,and a better-machined surface during machining.Consequently,the sustainability factor is improved due to minimized energy consumption and residual waste.In conclusion,the key challenges and future prospects in the ultrasonic-assisted cutting of titanium alloys are also discussed.This review article provides beneficial knowledge for manufactur-ers and researchers regarding ultrasonic vibration-assisted cutting of titanium alloy and will play an important role in achieving sustainability in the industry.
文摘Glass,with its valuable properties,finds extensive use in aerospace,optics,and biomedical fields.Owing to its low fracture toughness,glass typically fractures in a brittle manner during machining,resulting in poor surface quality.This paper presents an experimental investigation of vibration-assisted machining(VAM)techniques to enhance the machining of glass materials.A novel high-frequency two-dimensional VAM system specifically designed for glass is introduced,and slot milling experiments are conducted using ultrasonic high-frequency vibrations.A low-frequency nonresonant VAM system is also employed for comparison purposes.A comprehensive examination is made of the effects of various machining parameters,such as feed rate,cutting speeds,and vibration parameters,including vibration modes and amplitudes,on the machining performance of glass.Surface roughness,edge chipping generation,and tool wear are thoroughly characterized using scanning electron microscopy.The findings demonstrate that under specific machining and vibration parameters,the proposed ultrasonic vibration-assisted micro-milling(UVAMM)system can achieve a nanometric surface roughness Ra for glass.The UVAMM system offers enhanced surface quality,improved edge quality,and reduced tool wear compared with conventional machining techniques.This study provides valuable insights and directions for the application of 2D VAM systems in achieving superior machining results for glass components at small scales with nanometric surface finishes.
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supported by the Jilin Province Key Research and Development Plan Project(20240302066GX)the National Natural Science Foundation of China(Grant No.52075221)the Fundamental Research Funds for the Central Universities(2023-JCXK-02)。
文摘Micro/nano hierarchical structures could endow materials with various surface functions.However,the multilayer and multiscale characteristics of micro/nano hierarchical structures bring difficulties for their one step and controllable fabrication.Accordingly,based on tip-based fabrication techniques,this study proposed a micro-amplitude vibration-assisted scratching method by introducing a periodic backward displacement into the conventional scratching process,which enabled the synchronous creation of the microscale V-groove and nanoscale ripples,i.e.a typical micro/nano hierarchical structure.The experiments and finite element modeling were employed to explore the formation process and mechanism of the micro/nano hierarchical structures.Being different from conventional cutting,this method was mainly based on the plow mechanism,and it could accurately replicate the shape of the indenter on the material surface.The microscale V-groove was formed due to the scratching action,and the nanoscale ripple was formed due to the extrusion action of the indenter on the microscale V-groove’s surface.Furthermore,the relationships between the processing parameters and the dimensions of the micro/nano hierarchical structures were established through experiments,and optimized processing parameters were determined to achieve regular micro/nano hierarchical structures.By this method,complex patterns constructed by various micro/nano hierarchical structures were fabricated on both flat and curved surfaces,achieving diverse surface structural colors.
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)+4 种基金the Natural Science Foundation of Jiangsu Province(No.BK20210295)the Superior Postdoctoral Project of Jiangsu Province(No.2022ZB215)the Postgraduate Research&Practice Innovation Program of Jiangsu Province(KYCX23_0355)the Interdisciplinary Innovation Fund for Doctoral Students of Nanjing University of Aeronautics and Astronautics(KXKCXJJ202305)the Fundamental Research Funds for the Central Universities(Nos.NS2023028 and NG2024015)。
文摘Gamma titanium-aluminum intermetallic compounds(γ-TiAl)have gained considerable attentions in the aerospace industry due to their exceptional thermal resilience and comprehensive attributes,making them a prime example of lightweight and advanced materials.To address the frequent occurrence of burns and severe tool deterioration during the process of high-efficiency deep grinding(HEDG)onγ-TiAl alloys,ultrasonic vibration-assisted high-efficiency deep grinding(UVHEDG)has been emerged.Results indicate that in UVHEDG,the grinding temperature is on average 15.4%lower than HEDG due to the employment of ultrasonic vibrations,enhancing coolant penetration into the grinding area and thus reducing heat generation.Besides,UVHEDG possesses superior performance in terms of grinding forces compared to HEDG.As the material removal volume(MRV)increases,the tangential grinding force(F_(t))and normal grinding force(F_(n))of UVHEDG increase but to a lesser extent than in HEDG,with an average reduction of16.25%and 14.7%,respectively.UVHEDG primarily experiences microfracture of grains,whereas HEDG undergoes large-scale wear later in the process due to increased grinding forces.The surface roughness(R_(a))characteristics of UVHEDG are superior,with the average value of R_(a)decreasing by 46.5%compared to HEDG as MRV increases.The surface morphology in UVHEDG exhibits enhanced smoothness and a shallower layer of plastic deformation.Grinding chips generated by UVHEDG show a more shear-like shape,with the applied influence of ultrasonic vibration on chip morphology,thereby impacting material removal behaviors.These aforementioned findings contribute to enhanced machining efficiency and product quality ofγ-TiAl alloys after employing ultrasonic vibrations into HEDG.
基金Supported by Shandong Provincial Natural Science Foundation of China(Grant No.ZR2023QE041)China Postdoctoral Science Foundation(Grant No.2023M731862)National Natural Science Foundation of China(Grant No.51975112).
文摘Textured surfaces with certain micro/nano structures have been proven to possess some advanced functions,such as reducing friction,improving wear and increasing wettability.Accurate prediction of micro/nano surface textures is of great significance for the design,fabrication and application of functional textured surfaces.In this paper,based on the kinematic analysis of cutter teeth,the discretization of ultrasonic machining process,transformation method of coordinate systems and the cubic spline data interpolation,an integrated theoretical model was established to characterize the distribution and geometric features of micro textures on the surfaces machined by different types of ultrasonic vibration-assisted milling(UVAM).Based on the theoretical model,the effect of key process parameters(vibration directions,vibration dimensions,cutting parameters and vibration parameters)on tool trajectories and microtextured surface morphology in UVAM is investigated.Besides,the effect of phase difference on the elliptical shape in 2D/3D ultrasonic elliptical vibration-assisted milling(UEVAM)was analyzed.Compared to conventional numerical models,the method of the cubic spline data interpolation is applied to the simulation of microtextured surface morphology in UVAM,which is more suitable for characterizing the morphological features of microtextured surfaces than traditional methods due to the presence of numerous micro textures.The prediction of surface roughness indicates that the magnitude of ultrasonic amplitude in z-direction should be strictly limited in 1D rotary UVAM,2D and 3D UEVAM due to the unfavorable effect of axial ultrasonic vibration on the surface quality.This study can provide theoretical guidance for the design and fabrication of microtextured surfaces in UVAM.
基金Supported by National Key Research and Development Program of China(Grant Nos.2019YFA0708902,2022YFB3404002)Fundamental Research Funds for the Central Universities of China(Grant No.DUT22LAB501)+1 种基金National Science Foundation for Distinguished Young Scholars of China(Grant No.52325506)National Natural Science Foundation of China(Grant No.52275411)。
文摘C_(f)/SiC composites are characterized as anisotropic,heterogeneous,brittle,and hard materials.The process of manufacturing C_(f)/SiC composites using traditional machining techniques is prone to edge chipping damage and tool wear,which makes it difficult to meet the machining quality and machining accuracy.The purpose of this paper is to investigate the milling characteristics and damage assessment during ultrasonic vibration-assisted end milling(UVAEM)of C_(f)/SiC composites.Firstly,UVAEM experiments on C_(f)/SiC composites were carried out at different ultrasonic amplitudes and comparative experiments with conventional milling(CM).In addition,tool wear,surface roughness,surface micromorphology,milling force and subsurface damage(SSD)were measured and analysed.Finally,the SSD factors of C_(f)/SiC composites were established to quantify machining damage,and analyzed the effect of ultrasonic amplitude on SSD.Furthermore,the formation mechanism of SSD was investigated and discussed.The findings indicate that appropriate ultrasonic amplitude improves the surface quality by UVAEM,while excessive amplitude deteriorates the surface quality.During the UVAEM,micro/macro brittle fracture of the fibers on the surface occurs,leading to machining defects such as fiber breakage,fiber-interface debonding and pits.The milling force gradually decreases with the increase of ultrasonic amplitude.On the other hand,the forms of SSD in CM and UVAEM are mainly fiber pullout,subsurface crack,crack extension and machining pits.Matrix cracking and fiber pullout in SSD were affected by fiber orientation.Moreover,the introduction of ultrasonic vibration plays a significant contribution in the inhibition of the SSD in C_(f)/SiC composites.
基金the National Natural Science Foundation of China(No.51805284)the Key Scientific Research Projects of Colleges and Universities in Henan Province of China(No.19A460006)PhD Research Startup Fund Project of Pingdingshan University of China(No.PXY-BSQD-2018013)。
文摘Ultrasonic vibration-assisted ELID(UVA-ELID)grinding is utilized as a novel and highly efficient processing method for hard and brittle materials such as ceramics.In this study,the UVA-ELID grinding ZTA ceramics is employed to investigate the influence of thermomechanical loading on the characteristics of oxide film.Based on the fracture mechanics of material,the model of internal stress for oxide film damage is proposed.The thermomechanical loading is composed of mechanical force and the thermal stress generating from grinding temperature.The theoretical model is established for the mechanical force,thermal stress and internal stress respectively.Then the finite element analysis method is used to simulate the theoretical model.The mechanical force and grinding temperature is measured during the actual grinding test.During the grinding process,the effect of grinding wheel speed and grinding depth on the thermomechanical force and the characteristics of oxide film is analyzed.Compared with the conventional ELID(CELID)grinding,the mechanical force decreased by 25.6%and 22.4%with the increase of grinding wheel speed and grinding depth respectively,and the grinding temperature declined by 10.7%and12.8%during the UVA-ELID grinding.The thermal stress in the latter decreased by 16.3%and20.8%respectively,and internal stress reduced by 12.3%and 15.6%.It was experimentally found that the topographies of oxide layer on the surface of the wheel and the machined surface in the latter was better than that in the former.The results indicate that the action of ultrasonic vibration establish a significant effect on the processing.Subsequently,it should be well considered for future reference when processing the ZTA ceramics.
基金Project(2010-0008-277)supported by NCRC(National Core Research Center)Program through the National Research Foundation of Korea Funded by the Ministry of Education,Science and Technology
文摘The ultrafast laser based hybrid machining system was studied and a novel approach was demonstrated to improve laser machining quality on metals by vibrating the optical objective lens with a low frequency (500 Hz) and various displacements (0-16.5 μm) during a femtosecond laser machining process.The laser used in this experiment is an amplified Ti:sapphire femtosecond (10-15 s) laser system that generates 100 femtosecond pulses having an energy of 3.5 mJ/pulse with a 5 kHz repetition rate at a central wavelength of 790 nm.It is found that both the wall surface finish of the machined structures and the aspect ratio obtained using the frequency vibration assisted laser machining are improved compared with those derived via laser machining without vibration assistance.
基金supported by the National Natural Science Foundation of China(Nos.51875179 and 52275419).
文摘Ultrasonic vibration-assisted technology is widely utilized in the performance research and manufacturing process of metallic materials owing to its advantages of introducing highfrequency acoustic systems. However, the acoustic plasticity constitutive model and potential mechanism, involving Ti3Al intermetallic compounds, have not yet been clarified. Therefore, the Ultrasonic-K-M hybrid acoustic constitutive model of Ti3Al was established by considering the stress superposition, acoustic thermal softening, acoustic softening and acoustic residual hardening effects according to the dislocation density evolution theory and crystal plasticity theory. Meanwhile, the mechanical behavior of ultrasonic vibration-assisted tension(UVAT) and microstructure of ultrasonic vibration-assisted milling(UVAM) for Ti3Al was investigated. Dislocation density to be overcome from initial deformation to failure of Ti3Al was calculated in UVAT and was verified in UVAM. The results indicated that the Ultrasonic-K-M model showed a good agreement with the experimental data. There was an obviously softening phenomenon after introducing the ultrasonic energy field in the Ti3Al whole deformation region, and the degree of softening was positively correlated with amplitude. Furthermore, the maximum reduction ratio in yield strength of Ti3Al was16 % and the maximum reduction value in ultimate tensile strength was 206.91 MPa. The elongation rose first and then fell as amplitude enlarged, but only as the vibration was applied in the whole deformation region, the elongation was always greater than 14.58 %. In addition, The UVAM process significantly reduced the dislocation density increment to be overcome for Ti3Al material removal by 1.37 times, and promoted dislocation motion and cancellation to make twisted dislocations evolve into parallel dislocations. As the amplitude increased to 4 μm, the depth of the disturbed area of the plastic deformation layer increased by a maximum of 2.5 times.
基金This research was supported by Program of Tianjin Science and Technology(No.21ZXJBGX00020)the National Natural Science Foundation of China(Nos.51875404,52175275).
文摘In this paper,a novel,separable two-degrees-of-freedom stage with high-precision motion and resolution is proposed for the application of vibration-assisted micromilling.A separable design was realized on the basis of the detachable structure of the platform.Flexible stages with different dimensions and types can be utilized in the devices.A circular-fillet hinge is selected as the flexible unit with a parallel structure to realize output decoupling and reduce the coupling error between the two vibration directions.Analytical modeling is conducted to explore the static and dynamic characteristics of the stage.Results reveal a good agreement with the finite element simulation result.A series of experiments were conducted to assess the static and dynamic performances of the flexible stage,encompassing tests such as amplitude response,motion trajectory,and coupling trajectory.The results of these tests revealed that the designed vibration-assisted system exhibits precise movement capabilities.
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.
基金financially supported by the National Natural Science Foundation of China(Nos.51921003 and 51775275)National Key Laboratory of Science and Technology on Helicopter Transmission(Nanjing University of Aeronautics and Astronautics)(No.HTL-A-20G01)Postgraduate Research&Practice Innovation Program of Jiangsu Province(No.KYCX20_0179)。
文摘Ultrasonic vibration-assisted grinding(UVAG)is an effective and promising method for machining of hard-to-cut materials.This article proposed an ultrasonic vibration plate device enabling the longitudinal full-wave and transverse half-wave(L2T1)vibration mode for UVAG.The characteristics of two-dimensional coupled vibration in different directions were analyzed on the basis of apparent elastic method and finite element method.Furthermore,a correction factor was applied to correct the frequency error caused by the apparent elastic method.Finally,the comparative experiments between the conventional creep-feed grinding and UVAG of Inconel 718 nickel-based superalloy were carried out.The results indicate that the apparent elastic method with the correction factor is accurate for the design of plate device under the L2T1 vibration mode.Compared with the conventional creep-feed grinding,the UVAG causes the reduction of grinding force and the improvement of machined surface quality of Inconel 718 nickel-based superalloy.Furthermore,under the current experimental conditions,the optimal ultrasonic vibration amplitude is determined as 6μm,with which the minimum surface roughness is achieved.
基金supported by IHC Merwede B.V. as well as by Russian Foundation for Basic Research (Grant Nos. 13-0100349 and 14-01-31510)Russian Science Foundation (“support and development”, Grant No. 14-19-01637)Saint Petersburg University (Grant No. 6.38.243.2014)
文摘This paper outlines the results of experimental study of the dynamic rock failure based on the comparison of dry and saturated limestone samples obtained during the dynamic compression and split tests. The tests were performed using the Kolsky method and its modifications for dynamic splitting. The mechanical data(e.g. strength, time and energy characteristics) of this material at high strain rates are obtained. It is shown that these characteristics are sensitive to the strain rate. A unified interpretation of these rate effects, based on the structuraletemporal approach, is hereby presented. It is demonstrated that the temporal dependence of the dynamic compressive and split tensile strengths of dry and saturated limestone samples can be predicted by the incubation time criterion. Previously discovered possibilities to optimize(minimize) the energy input for the failure process is discussed in connection with industrial rock failure processes. It is shown that the optimal energy input value associated with critical load, which is required to initialize failure in the rock media, strongly depends on the incubation time and the impact duration. The optimal load shapes, which minimize the momentum for a single failure impact, are demonstrated. Through this investigation, a possible approach to reduce the specific energy required for rock cutting by means of high-frequency vibrations is also discussed.
基金supported by the National Natural Science Foundation of China(Grant Nos.92160301,92060203,52175415,and 52205475)the Science Center for Gas Turbine Project(Grant No.P2023-B-IV-003-001)+1 种基金the Natural Science Foundation of Jiangsu Province,China(Grant No.BK20210295)the State Key Laboratory of Mechanics and Control for Aerospace Structures(Nanjing University of Aeronautics and Astronautics,China)(Grant No.MCAS-S-0423G02).
文摘Continuous fiber-reinforced metal matrix composites(CFMMCs),reinforced by ceramic fibers(e.g.,Al_(2)O_(3)and SiC fibers)in a tough metal matrix,are extensively utilized in aerospace applications,such as engine casings and piston rods,because of their excellent high-temperature resistance and creep resistance.However,their heterogeneous composition presents machining challenges,including fiber pull-out,matrix adhesion,and increased tool wear.Ultrasonic vibration-assisted grinding(UVAG)effectively reduces grinding forces and abrasive wear.However,research on abrasive machining of specific CFMMCs is lacking.This study conducted single-grain cubic boron nitride grinding on SiC_(f)/TC17 with UVAG and compared the material removal mechanisms along two different directions(longitudinal fiber[LF]and transverse fiber[TF]).A simulation model was proposed to reveal the stress distribution and its propagation.Results showed that UVAG could effectively reduce grinding forces along both directions,with an average reduction of about 17.8%compared with conventional grinding.SiC fibers were removed in three models:micro-fractures,macro-fractures,and pull-outs.The introduction of ultrasonic energy mitigated fiber damage.The simulation model was consistent with Removal Model 1.The matrix’s surface stress during grinding along LF was more concentrated than that during grinding along TF under the action of the abrasive grain.The proposed model helps understand the removal behavior of CFMMCs.This research is expected to enhance the comprehension of abrasive machining of CFMMCs and facilitate their application in the aerospace field.
基金The authors gratefully acknowledge supports of the National Natural Science Foundation of China(Grant No.52105452)High Level Personnel Project of Jiangsu Province(Grant No.JSSCBS20210188)+3 种基金Central University Basic Research Fund of China(Grant No.NT2022017)Jiangsu Key Laboratory of Precision and Micro-Manufacturing Technology(Grant No.56XAC22006)Nanjing Foundation for Returnees(Grant No.1005-YQR21043)Foundation of Jiangsu Science and Technology Association Young Talents(Grant No.JSTJ-2022-073).
文摘Textured surfaces have been widely applied in many fields due to their excellent functional performances.Although several micro-scale surface texturing techniques have been used to fabricate surface textures,most are either very expensive,have material limitations,or lack flexibility.In this study,a novel textured surface generation method using vibration-assisted ball-end milling with a non-resonant vibrator is proposed.Firstly,the configuration of the vibration-assisted ball-end milling system is introduced.Then,the trajectories of the cutting edges are modeled and analyzed.Furthermore,an analysis of a non-resonant vibrator is conducted.Finally,surface texture machining experiments are conducted,and the feasibility of the proposed vibration-assisted ball-end milling method for surface texture fabrication is verified.
基金supported by the National Natural Science Foundation of China (Grant Nos.51921003,92160301,52175415 and 52205475)the Science Center for Gas Turbine Project,China (Grant No.P2022-A-IV-002-001)+1 种基金the Natural Science Foundation of Jiangsu Province,China (Grant No.BK20210295)the Postgraduate Research&Practice Innovation Program of Jiangsu Province,China (Grant No.KYCX20_0179).
文摘Ultrasonic vibration-assisted grinding(UVAG)is an advanced hybrid process for the precision machining of difficult-to-cut materials.The resonator is a critical part of the UVAG system.Its performance considerably influences the vibration amplitude and resonant frequency.In this work,a novel perforated ultrasonic vibration platform resonator was developed for UVAG.The holes were evenly arranged at the top and side surfaces of the vibration platform to improve the vibration characteristics.A modified apparent elasticity method(AEM)was proposed to reveal the influence of holes on the vibration mode.The performance of the vibration platform was evaluated by the vibration tests and UVAG experiments of particulate-reinforced titanium matrix composites.Results indicate that the reasonable distribution of holes helps improve the resonant frequency and vibration mode.The modified AEM,the finite element method,and the vibration tests show a high degree of consistency for developing the perforated ultrasonic vibration platform with a maximum frequency error of 3%.The employment of ultrasonic vibration reduces the grinding force by 36%at most,thereby decreasing the machined surface defects,such as voids,cracks,and burnout.
