Cubic boron nitride(cBN)grinding wheels play a pivotal role in precision machining,serving as indispensable tools for achieving exceptional surface quality.Ensuring the sharpness of cBN grains and optimizing the grind...Cubic boron nitride(cBN)grinding wheels play a pivotal role in precision machining,serving as indispensable tools for achieving exceptional surface quality.Ensuring the sharpness of cBN grains and optimizing the grinding wheel’s chip storage capacity are critical factors.This paper presents a study on the metal-bonded segments and single cBN grain samples using the vacuum sintering method.It investigates the impact of blasting parameters-specifically silicon carbide(SiC)abrasive size,blasting distance,and blasting time-on the erosive wear characteristics of both the metal bond and abrasive.The findings indicate that the abrasive size and blasting distance significantly affect the erosive wear performance of the metal bond.Following a comprehensive analysis of the material removal rate of the metal bond and the erosive wear condition of cBN grains,optimal parameters for the working layer are determined:a blasting distance of 60 mm,a blasting time of 15 s,and SiC particle size of 100#.Furthermore,an advanced simulation model investigates the dressing process of abrasive blasting,revealing that the metal bond effectively inhibits crack propagation within cBN abrasive grains,thereby enhancing fracture toughness and impact resistance.Additionally,a comparative analysis is conducted between the grinding performance of porous cBN grinding wheels and vitrified cBN grinding wheels.The results demonstrate that using porous cBN grinding wheels significantly reduces grinding force,temperature,and chip adhesion,thereby enhancing the surface quality of the workpiece.展开更多
Microneedle(MN)is a medical device containing an array of needles with a micrometer-scale.It can penetrate the human stratum corneum painlessly and efficiently for treatment and diagnosis purposes.Currently,the materi...Microneedle(MN)is a medical device containing an array of needles with a micrometer-scale.It can penetrate the human stratum corneum painlessly and efficiently for treatment and diagnosis purposes.Currently,the materials commonly used to manufacture MNs include silicon,polymers,ceramics and metals.Metallic MNs(MMNs)have drawn significant attention owing to its superior mechanical properties,machinability,and biocompatibility.This paper is a state-of-the-art review of the structure,fabrication technologies,and applications of MMNs.According to the relative position of the axis of MN and the plane of the substrate,MMNs can be divided into in-plane and out-of-plane.Solid,hollow,coated and porous MMNs are also employed to characterize their internal and surface structures.Until now,numerous fabrication technologies,including cutting tool machining,non-traditional machining,etching,hot-forming,and additive manufacturing,have been used to fabricate MMNs.The recent advances in the application of MMNs in drug delivery,disease diagnosis,and cosmetology are also discussed in-depth.Finally,the shortcomings in the fabrication and application of MMNs and future directions for development are highlighted.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
The current method for inspecting microholes in printed circuit boards(PCBs)involves preparing slices followed by optical microscope measurements.However,this approach suffers from low detection efficiency,poor reliab...The current method for inspecting microholes in printed circuit boards(PCBs)involves preparing slices followed by optical microscope measurements.However,this approach suffers from low detection efficiency,poor reliability,and insufficient measurement stability.Micro-CT enables the observation of the internal structures of the sample without the need for slicing,thereby presenting a promising new method for assessing the quality of microholes in PCBs.This study integrates computer vision technology with computed tomography(CT)to propose a method for detecting microhole wall roughness using a U-Net model and image processing algorithms.This study established an unplated copper PCB CT image dataset and trained an improved U-Net model.Validation of the test set demonstrated that the improved model effectively segmented microholes in the PCB CT images.Subsequently,the roughness of the holes’walls was assessed using a customized image-processing algorithm.Comparative analysis between CT detection based on various edge detection algorithms and slice detection revealed that CT detection employing the Canny algorithm closely approximates slice detection,yielding range and average errors of 2.92 and 1.64μm,respectively.Hence,the detection method proposed in this paper offers a novel approach for nondestructive testing of hole wall roughness in the PCB 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
Improving the thermal conductivity(TC)of diamond–metal composites has always been a significant challenge in the field of thermal management.In this paper,diamond/Al composites are systematically studied,and the infl...Improving the thermal conductivity(TC)of diamond–metal composites has always been a significant challenge in the field of thermal management.In this paper,diamond/Al composites are systematically studied,and the influence of the holding time(10–120 min)on interface structure and TC is discussed.The results of this research show that longterm thermal diffusion sintering can achieve dense interfacial bonding in diamond/Al composites,enhancing their TC.Diamond/Al composites with 50 vol%of 900μm diamond attain the highest TC value of 888.73 W·m^(-1)·K^(-1)under sintering conditions of 650?C,50 MPa,and 120 min—nearly 92%of the theoretical value predicted by the Maxwell model.This study establishes that high TC can be achieved through long-term thermal diffusion alone,without the need for complex diamond surface coating or substrate alloying.展开更多
基金Supported by National Natural Science Foundation of China(Grant Nos.92160301,92060203,52175415,52205475,and 52205493)Science Center for Gas Turbine Project(Grant Nos.P2022-AB-IV-002-001 and P2023-B-IV-003-001)+3 种基金Jiangsu Provincial Natural Science Foundation(Grant No.BK20210295)the Huaqiao University Engineering Research Center of Brittle Materials Machining(Grant No.2023IME-001)Foundation of Graduate Innovation Centre in NUAA(Grant No.XCXJH20230509)Fundamental Research Funds for the Central Universities(Grant Nos.NS2023028 and NG2024015).
文摘Cubic boron nitride(cBN)grinding wheels play a pivotal role in precision machining,serving as indispensable tools for achieving exceptional surface quality.Ensuring the sharpness of cBN grains and optimizing the grinding wheel’s chip storage capacity are critical factors.This paper presents a study on the metal-bonded segments and single cBN grain samples using the vacuum sintering method.It investigates the impact of blasting parameters-specifically silicon carbide(SiC)abrasive size,blasting distance,and blasting time-on the erosive wear characteristics of both the metal bond and abrasive.The findings indicate that the abrasive size and blasting distance significantly affect the erosive wear performance of the metal bond.Following a comprehensive analysis of the material removal rate of the metal bond and the erosive wear condition of cBN grains,optimal parameters for the working layer are determined:a blasting distance of 60 mm,a blasting time of 15 s,and SiC particle size of 100#.Furthermore,an advanced simulation model investigates the dressing process of abrasive blasting,revealing that the metal bond effectively inhibits crack propagation within cBN abrasive grains,thereby enhancing fracture toughness and impact resistance.Additionally,a comparative analysis is conducted between the grinding performance of porous cBN grinding wheels and vitrified cBN grinding wheels.The results demonstrate that using porous cBN grinding wheels significantly reduces grinding force,temperature,and chip adhesion,thereby enhancing the surface quality of the workpiece.
基金Supported by Guangdong Provincial Key-Area Research and Development Program(Grant No.2023B0101200014)Guangdong Provincial Natural Science Foundation(Grant No.2024A1515010440).
文摘Microneedle(MN)is a medical device containing an array of needles with a micrometer-scale.It can penetrate the human stratum corneum painlessly and efficiently for treatment and diagnosis purposes.Currently,the materials commonly used to manufacture MNs include silicon,polymers,ceramics and metals.Metallic MNs(MMNs)have drawn significant attention owing to its superior mechanical properties,machinability,and biocompatibility.This paper is a state-of-the-art review of the structure,fabrication technologies,and applications of MMNs.According to the relative position of the axis of MN and the plane of the substrate,MMNs can be divided into in-plane and out-of-plane.Solid,hollow,coated and porous MMNs are also employed to characterize their internal and surface structures.Until now,numerous fabrication technologies,including cutting tool machining,non-traditional machining,etching,hot-forming,and additive manufacturing,have been used to fabricate MMNs.The recent advances in the application of MMNs in drug delivery,disease diagnosis,and cosmetology are also discussed in-depth.Finally,the shortcomings in the fabrication and application of MMNs and future directions for development are highlighted.
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 National Natural Science Foundation of China(Grant Nos.52122510 and 52375415).
文摘The current method for inspecting microholes in printed circuit boards(PCBs)involves preparing slices followed by optical microscope measurements.However,this approach suffers from low detection efficiency,poor reliability,and insufficient measurement stability.Micro-CT enables the observation of the internal structures of the sample without the need for slicing,thereby presenting a promising new method for assessing the quality of microholes in PCBs.This study integrates computer vision technology with computed tomography(CT)to propose a method for detecting microhole wall roughness using a U-Net model and image processing algorithms.This study established an unplated copper PCB CT image dataset and trained an improved U-Net model.Validation of the test set demonstrated that the improved model effectively segmented microholes in the PCB CT images.Subsequently,the roughness of the holes’walls was assessed using a customized image-processing algorithm.Comparative analysis between CT detection based on various edge detection algorithms and slice detection revealed that CT detection employing the Canny algorithm closely approximates slice detection,yielding range and average errors of 2.92 and 1.64μm,respectively.Hence,the detection method proposed in this paper offers a novel approach for nondestructive testing of hole wall roughness in the PCB 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Project supported by the National Natural Science Foundation of China(Grant Nos.12274372 and 12274373)the Major Science and Technology Projects of Henan Province(Grant No.231100230300)。
文摘Improving the thermal conductivity(TC)of diamond–metal composites has always been a significant challenge in the field of thermal management.In this paper,diamond/Al composites are systematically studied,and the influence of the holding time(10–120 min)on interface structure and TC is discussed.The results of this research show that longterm thermal diffusion sintering can achieve dense interfacial bonding in diamond/Al composites,enhancing their TC.Diamond/Al composites with 50 vol%of 900μm diamond attain the highest TC value of 888.73 W·m^(-1)·K^(-1)under sintering conditions of 650?C,50 MPa,and 120 min—nearly 92%of the theoretical value predicted by the Maxwell model.This study establishes that high TC can be achieved through long-term thermal diffusion alone,without the need for complex diamond surface coating or substrate alloying.
