The increasing demand for high-end equipment in crucial sectors such as aerospace,aeronautics, energy, power, information and electronics continues growing. However, the manufacturing of such advanced equipment poses ...The increasing demand for high-end equipment in crucial sectors such as aerospace,aeronautics, energy, power, information and electronics continues growing. However, the manufacturing of such advanced equipment poses significant challenges owing to high-level requirements for loading, transmission, conduction, energy conversion, and stealth. These challenges are amplified by complex structures, hard-to-cut materials, and strict standards for surface integrity and precision. To overcome these barriers in high-end equipment manufacturing, high-performance manufacturing(HPM) has emerged as an essential solution.This paper firstly discusses the key challenges in manufacturing technology and explores the essence of HPM, outlining a quantitative relationship between design and manufacturing.Subsequently, a generalized framework of HPM is proposed, accompanied by an in-depth exploration of the foundational elements and criteria. Ultimately, the feasible approaches and enabling technologies, supported by the analysis of two illustrative case studies are demonstrated. It is concluded that HPM is not just a precision and computational manufacturing framework with a core focus on multiparameter correlation in design, manufacturing, and service environments. It also represents a performance-geometry-integrated manufacturing framework for an accurate guarantee of the optimal performance.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
In order to address the urgent demand for lightweight components in the aerospace,a laser-arc hybrid additive manufacturing(LAHAM)is innovatively applied to the Mg-Gd-Y-Zr alloy in this study.The results show that com...In order to address the urgent demand for lightweight components in the aerospace,a laser-arc hybrid additive manufacturing(LAHAM)is innovatively applied to the Mg-Gd-Y-Zr alloy in this study.The results show that compared with wire arc additive manufacturing(WAAM),the grain size and texture strength of LAHAM were reduced by about 26% and 27% respectively.The β phase at grain boundaries are effectively mitigated.In LAHAM,the nanoscale β phase(Mg_(24)(Gd,Y)_(5)+Mg_(5)(Gd,Y))and β_(1) phase(Mg_(3)(Gd,Y))were uniformly distributed in the grain boundary.There were only nanoscale β phase distributed around the enriched second phase in WAAM.The size and type of nanoparticles directly affect the mechanical properties of alloys.The tensile strength and yield strength of WAAM specimen were about 228 MPa,152 MPa.Compared with WAAM,the tensile strength and yield strength of LAHAM were increased by about 12% and 15%,reaching 254 MPa and 175 MPa.The contribution of precipitation strengthening is about 42%.This study provides a new perspective for the systematic application and fabrication of Mg-Gd-Y-Zr alloy.展开更多
Recently,rapid and cost-effective additive manufacturing solutions for lightweight aluminum alloys with excellent high-temperature mechanical properties have been increasingly in demand.In this study,we combined laser...Recently,rapid and cost-effective additive manufacturing solutions for lightweight aluminum alloys with excellent high-temperature mechanical properties have been increasingly in demand.In this study,we combined laser-arc hybrid additive manufacturing with solution and artificial aging treatments to achieve Al-Zn-Mg-Cu alloy with favorable high-temperature strength via microstructure control.Hydrogen pores became the major defect in the as-deposited and heat-treated specimens.The continuous distribution of eutectics with hard-brittle characteristics at the grain boundaries was destructed following heat treat-ment.High-densityηprecipitates were uniformly dispersed in the heat-treated Al-Zn-Mg-Cu alloy,whereas appeared coarsened and dissolved at 473 K,owing to the rapid diffusion of Zn and Mg.The average 0.2%yield strength(318±16 MPa)and ultimate tensile strength(362±20 MPa)at 473 K af-ter heat treatment were enhanced by approximately 58%and 51%,respectively,compared to those of the as-deposited specimen.In addition,theηprecipitates contributed to lattice distortions and strain fields,which prevented dislocation motion and increased slip deformation resistance at high temper-atures.The as-deposited specimen exhibited intergranular fracture at 473 K,with cracks preferring to propagate along the aggregated eutectics.However,crack propagation proceeded in the sections with more pores in the heat-treated specimen.Our approach may provide a valid option for achieving alu-minum alloys with excellent high-temperature mechanical properties.展开更多
Water dissolution ultraprecision continuous polishing is a nontraditional machining method specifically designed for water-soluble crystals.The aim of this study is primarily to reduce the surface roughness for small ...Water dissolution ultraprecision continuous polishing is a nontraditional machining method specifically designed for water-soluble crystals.The aim of this study is primarily to reduce the surface roughness for small sizes from an experimental standpoint.A trajectory uniformity simulation analysis is carried out for a consistent material removal.A material removal model is developed based on the water dissolution principle and kinematic analysis.Numerical simulations of single-and multiple-water-core polishing trajectories are performed to explore the influences of the processing parameters such as movement form,number of water cores,speed ratio,polishing time,and period ratio on the material removal uniformity.The material removal rate is calculated according to the Preston equation.The trajectory density nonuniformity is utilized to evaluate the global uniformity of the trajectory distributions and optimize the processing parameters for a better material removal uniformity.Verification experiments are conducted on a large-size ultraprecision continuous polisher using a typical potassium dihydrogen phosphate(KDP)crystal with a water-soluble structure.The edge collapse is improved from 51.499μm to 1.477μm by trajectory uniformity optimization.The changing trends of line profile variations in the validation experiment and simulation are similar.An ultrasmooth surface of a 180 mm×180 mm KDP crystal with a surface roughness root mean square of 1.718 nm is obtained after water dissolution ultraprecision continuous polishing.This study provides a comprehensive method for evaluation of material removal uniformity,which is valuable for the realization of high-quality machining for water-soluble crystals.展开更多
As one of the most important terminals in machining, cutting tools have been widely used for components manufacturing in aerospace and other industries. The quality of these components and processing efficiency are cl...As one of the most important terminals in machining, cutting tools have been widely used for components manufacturing in aerospace and other industries. The quality of these components and processing efficiency are closely linked to the performance of cutting tools. Therefore, it is essential and critical to inspect the cutting tools and monitor the condition during the stage of manufacturing and machining. This review aims to discuss and summarize the key problems, methods,and techniques from the perspective of the tool geometric and the physical quantities measurement,including machine vision, physical sensors and data processing. It is worth mentioning that we focus on the topic of precision measurement methods and discuss universal solutions by identifying the common characteristics of the measured quantities. Eventually, the challenges and future trends for the development of in-depth research and practical applications are concluded. The research and application of precise measurement techniques for geometric and physical quantities will better promote the development of intelligent manufacturing.展开更多
SiC_(f)/SiC ceramic matrix composites(SiC_(f)/SiC composites)are difficult to drill small holes due to their heterogeneity,high hardness,and low electrical conductivity.In order to solve the difficulties of poor quali...SiC_(f)/SiC ceramic matrix composites(SiC_(f)/SiC composites)are difficult to drill small holes due to their heterogeneity,high hardness,and low electrical conductivity.In order to solve the difficulties of poor quality and low efficiency when drilling small holes,a novel femtosecond laser rotary drilling(FLRD)technique is proposed.Beam kinematic paths and experimental studies were carried out to analyze the effects of processing parameters on the drilling results in the two-step drilling process.In the through-hole drilling stage,the material removal rate increases with increasing laser power,decreasing feed speed and decreasing pitch.As for the finishing stage of drilling,the exit diameter increased with increasing laser power and decreasing feed speed.The drilling parameters were selected by taking the processing efficiency of through-hole and the quality of finished hole as the constraint criteria.Holes with a diameter of 500μm were drilled using FLRD in 3 mm thick SiC_(f)/SiC composites with a drilling time<150 s.The hole aspect ratio was 6,the taper<0.2°,and there was no significant thermal damage at the orifice or the wall of the hole.The FLRD provides a solution for precision machining of small holes in difficult-to-machine materials by offering the advantages of high processing quality and short drilling times.展开更多
Trochoidal milling is known for its advantages in machining difficult-to-machine materials as it facilitates chip removal and tool cooling.However,the conventional trochoidal tool path presents challenges such as lowe...Trochoidal milling is known for its advantages in machining difficult-to-machine materials as it facilitates chip removal and tool cooling.However,the conventional trochoidal tool path presents challenges such as lower machining efficiency and longer machining time due to its time-varying cutter-workpiece engagement angle and a high percentage of non-cutting tool paths.To address these issues,this paper introduces a parameter-variant trochoidal-like(PVTR)tool path planning method for chatter-free and high-efficiency milling.This method ensures a constant engagement angle for each tool path period by adjusting the trochoidal radius and step.Initially,the nonlinear equation for the PVTR toolpath is established.Then,a segmented recurrence method is proposed to plan tool paths based on the desired engagement angle.The impact of trochoidal tool path parameters on the engagement angle is analyzed and coupled this information with the milling stability model based on spindle speed and engagement angle to determine the desired engagement angle throughout the machining process.Finally,several experimental tests are carried out using the bull-nose end mill to validate the feasibility and effectiveness of the proposed method.展开更多
Atomic surfaces are strictly required by high-performance devices of diamond.Nevertheless,diamond is the hardest material in nature,leading to the low material removal rate(MRR)and high surface roughness during machin...Atomic surfaces are strictly required by high-performance devices of diamond.Nevertheless,diamond is the hardest material in nature,leading to the low material removal rate(MRR)and high surface roughness during machining.Noxious slurries are widely used in conventional chemical mechanical polishing(CMP),resulting in the possible pollution to the environment.Moreover,the traditional slurries normally contain more than four ingredients,causing difficulties to control the process and quality of CMP.To solve these challenges,a novel green CMP for single crystal diamond was developed,consisting of only hydrogen peroxide,diamond abrasive and Prussian blue(PB)/titania catalyst.After CMP,atomic surface is achieved with surface roughness Sa of 0.079 nm,and the MRR is 1168 nm·h^(-1).Thickness of damaged layer is merely 0.66 nm confirmed by transmission electron microscopy(TEM).X-ray photoelectron spectroscopy,electron paramagnetic resonance and TEM reveal that·OH radicals form under ultraviolet irradiation on PB/titania catalyst.The·OH radicals oxidize diamond,transforming it from monocrystalline to amorphous atomic structure,generating a soft amorphous layer.This contributes the high MRR and formation of atomic surface on diamond.The developed novel green CMP offers new insights to achieve atomic surface of diamond for potential use in their high-performance devices.展开更多
Drug research and development(R&D)plays a crucial role in supporting public health.However,the traditional drug-discovery paradigm is hindered by significant drawbacks,including high costs,lengthy development time...Drug research and development(R&D)plays a crucial role in supporting public health.However,the traditional drug-discovery paradigm is hindered by significant drawbacks,including high costs,lengthy development timelines,high failure rates,and limited output of new drugs.Recent advances in micro/nanotechnology,along with progress in computer science,have positioned microfluidics and artificial intelligence(AI)as promising transformative tools for drug development.Microfluidics offers miniaturized,multiplexed,and versatile platforms for high-dimensional data acquisition,while AI enables the rapid processing of complex,large-scale microfluidic data;together,they are accelerating a paradigm shift in the drug-discovery process.This paper first outlines the mainstream microfluidic strategies and AI models used in drug R&D.It then summarizes and discusses real-world applications of the integrated use of these technologies across various stages of drug discovery,including early drug discovery,drug screening,drug evaluation,drug manufacturing,and drug delivery systems.Finally,the paper examines the main limitations of microfluidics and AI in drug R&D and offers an outlook on the future convergence of these technologies.展开更多
Due to the high hardness and low fracture toughness of the single crystal silicon(SCS),it is highly susceptible to microscopic cracks and subsurface damage during processing.In this paper,we propose to adjust the mech...Due to the high hardness and low fracture toughness of the single crystal silicon(SCS),it is highly susceptible to microscopic cracks and subsurface damage during processing.In this paper,we propose to adjust the mechanical properties of SCS by cold plasma jet,and systematically investigate the influences of the plasma on material deformation and damage mechanisms by nanoscratch tests.The results indicate that the plasma can increase the critical normal force for the plastic-brittle(P-B)conversion of SCS.Compared with the ordinary nanoscratch test,the critical force for P-B conversion of plasma-assisted scratching at 1μm/s can increase from 43.6 to 66.4 mN.Increasing the scratching speed under ordinary conditions can enhance the plastic deformability of SCS to some extent,but its effect is not as effective as that of plasma;in addition,the increased scratching speed causes the shear bands(SBs)to lack time to propagate,so the quantity of SBs under plasma-assisted scratching at 10μm/s is reduced compared to 1μm/s.From subsurface damage topographies,the highly localized amorphous SBs cause the generation of subsurface cracks.The cold plasma can alleviate cracks on the scratched subsurface of SCS by introducing multiple SBs and stacking faults.This paper may provide a novel strategy for high-efficiency and low-damage ultra-precision machining of hard and brittle materials.展开更多
Three-dimensional(3D)conductive structures significantly reduce flexible circuit complexity and enhance circuit integration.Direct extrusion printing technology offers the advantages of various material applicability ...Three-dimensional(3D)conductive structures significantly reduce flexible circuit complexity and enhance circuit integration.Direct extrusion printing technology offers the advantages of various material applicability and high flexibility for fabricating filamentary interconnects.The printing resolution is,however,highly dependent on the needle size.A micro-printing method was proposed based on fluid drawing to fabricate freestanding 3D conductive structures.The delicate structure is drawn out under the tension when printing.The printing material is a high-viscosity ink composed of silver nanoparticles(AgNPs)and polyvinylpyrrolidone(PVP).The viscosity is controlled by evaporating the ink’s solvent for drawing prints.This unique printing method utilizes a single needle,controlled by precise air pressure and speed,to construct 3D filamentary structures with varied wire widths.The 3D conductive structures exhibit superior structural retention and enhanced conductivity by thermal treatment.The drawing printing method has been successfully implemented on flexible circuits,including light-emitting diode(LED)arrays,thermal imaging displays,and multivibrator circuits.This work establishes a novel paradigm for flexible electronics manufacturing through fluid-drawing printing,achieving unprecedented customization and compatibility in fabricating 3D interconnects.展开更多
The double-sided lapping process is extensively employed in the manufacturing of wafers,optical windows,and seal rings due to its high efficiency and ability to achieve precise flatness.However,limited research has ex...The double-sided lapping process is extensively employed in the manufacturing of wafers,optical windows,and seal rings due to its high efficiency and ability to achieve precise flatness.However,limited research has explored the thickness uniformity among different workpieces after double-sided lapping,and the underlying mechanism remains unclear.To address the demand for higher precision,this paper first analyzed the relative kinematic model between the workpiece and the lapping plate to clarify the causes of thickness variations among workpieces after double-sided lapping.Subsequently,a finite element method(FEM)model was developed to account for the pressure distribution on the workpiece surfaces at the initial stage of the process.The results indicate that the number of workpieces influences the final thickness variation.Then,various sets of thin copper plates with different thicknesses were lapped,and the findings revealed that five copper plates processed simultaneously exhibited more uniform thickness compared to the three plates.The experimental results align well with the theoretical analysis.Ultimately,a thickness variation of less than 6μm was achieved on five copper plates measuringΦ100×2.9 mm.This study presents a comprehensive analysis of the mechanisms influencing thickness uniformity in the double-sided lapping process and provides practical guidelines for optimizing the process to achieve stringent precision standards in industrial applications.展开更多
Marine biofouling is the undesired attachment and formation of marine organisms on surfaces,which adversely affects ship maintenance,economic costs,and ecosystem health.Despite remarkable advancements in antifouling c...Marine biofouling is the undesired attachment and formation of marine organisms on surfaces,which adversely affects ship maintenance,economic costs,and ecosystem health.Despite remarkable advancements in antifouling coatings,developing formulations that simultaneously achieve environmental benign and high antifouling performances remains a critical challenge.Herein,drawing inspiration from the natural antifouling mechanisms including the superhydrophobicity of lotus leaves and biochemical defense of coral mucus,we developed a Superhydrophobic Antifouling Coating(SHAC)incorporating coral mucus-derived agents.This biomimetic design synergistically integrates physical anti-adhesion of superhydrophobic surfaces with chemical repellency of antifouling agents,yielding outstanding antifouling performance.The SHAC demonstrates remarkable durability(withstanding 100 abrasion cycles),sustained superhydrophobicity(contact angle>150°),and outstanding antifouling efficacy(92%bacterial and 96%algal inhibition).Marine field tests demonstrate significant reduction in fouling organism attachment over 30 days.Our work presents an eco-friendly and high-performance solution to marine biofouling,bridging the gap between sustainability and effectiveness in antifouling technology.展开更多
Thin-walled parts have been widely employed as critical components in high-performance equipment due to the high specific strength and light weight.However,owing to their relatively weak rigidity and poor damping prop...Thin-walled parts have been widely employed as critical components in high-performance equipment due to the high specific strength and light weight.However,owing to their relatively weak rigidity and poor damping properties,chatter vibration is likely to occur during the milling process,which severely deteriorates surface quality and decreases machining productivity.Therefore,chatter suppression is essential for improving the dynamic machinability of thin-walled structures and has attracted extensive attention over the past few decades.This paper reviews the current state of the art in research concerning chatter suppression during the milling of thin-walled workpieces.In consideration of the dynamic characteristics of this process,the challenges in design and application of chatter attenuation methods are highlighted.Moreover,various chatter suppression techniques,involving passive,active,and semi-active methods,are comprehensively discussed in terms of basic concepts,working mechanism,optimal design,and application.Finally,future research opportunities in chatter mitigation technology for thin-wall milling are recommended.展开更多
Laser-directed energy deposition(LDED)technology has demonstrated great potential for the rapid and integrated fabrication of nickel-based superalloy components.The plastic deformation-assisted method is crucial for a...Laser-directed energy deposition(LDED)technology has demonstrated great potential for the rapid and integrated fabrication of nickel-based superalloy components.The plastic deformation-assisted method is crucial for achieving grain refinement and microstructural homogeneity in LDED-fabricated superalloys.However,existing methods suffer from uniformity constraints owing to their high deformation resistance,which significantly limits their application in load-bearing components.To address these issues,a synchronous-hot-forging-assisted(SHFA)LDED additive manufacturing method was proposed,and its effects on the macroscopic morphology,microstructure,and mechanical properties of GH4169 nickel-based alloy specimens were systematically compared.The results demonstrated up to 30.1%average plastic deformation in hot-forging components while maintaining good surface flatness.The synergistic effect of dislocation accumulation and dynamic recrystallization during hot forging enables dramatic grain refinement,reducing the average grain size by 89.1%(from 168.5μm to 18.4μm)while weakening texture intensity from 15.31 to 2.15,ultimately promoting equiaxed grain formation.The pores of hot-forging components changed from fine round to flat,the porosity decreased from 0.264%to 0.089%,and the densification level was significantly improved.With the increase in the synchronous hot-forging force,the average ultimate tensile strength of hot-forging components can reach 1175.1 MPa,while the anisotropy difference is gradually weakened.The SHFA-LDED process not only achieves excellent grain refinement and microstructure homogenization but also enhances mechanical properties,providing a new technical path for the additive manufacturing of high-performance nickel-based superalloy components.展开更多
Leveraging surface texturing to realize significant friction reduction at contact interfaces has emerged as a preferred technique among tribology experts,boosting tribological energy efficiency and sustainability.This...Leveraging surface texturing to realize significant friction reduction at contact interfaces has emerged as a preferred technique among tribology experts,boosting tribological energy efficiency and sustainability.This review systematically demonstrates optimization strategies,advanced manufacturing methods,typical applications,and outlooks of technical challenges toward surface texturing for friction reduction.Firstly,the lubricated contact models of microtextures are introduced.Then,we provide a framework of state-of-the-art research on synergistic friction optimization strategies of microtexture structures,surface treatments,liquid lubricants,and external energy fields.A comparative analysis evaluates the strengths and weaknesses of manufacturing techniques commonly employed for microtextured surfaces.The latest research advancements in microtextures in different application scenarios are highlighted.Finally,the challenges and directions of future research on surface texturing technology are briefly addressed.This review aims to elaborate on the worldwide progress in the optimization,manufacturing,and application of microtexture-enabled friction reduction technologies to promote their practical utilizations.展开更多
The z-axis-inclined 3D printing process using short carbon fiber-reinforced thermoplastic composites offers the potential for the support-free fabrication of complex structures and theoretically unlimited extension of...The z-axis-inclined 3D printing process using short carbon fiber-reinforced thermoplastic composites offers the potential for the support-free fabrication of complex structures and theoretically unlimited extension of printed components.It has emerged as a promising approach for in-orbit manufacturing of high-performance thermoplastic composite truss structures.However,extreme conditions of the space environment,such as high vacuum and fluctuating high-low temperatures,significantly alter the heat-transfer behavior during the printing process,often resulting in dimensional inaccuracies and degraded mechanical performance.Existing process optimization strategies fail to account for the coupled effects of vacuum and thermal extremes,limiting their applicability in guiding process design under varying vacuum temperature conditions.To address this gap,this study establishes a truss3D printing experimental platform with in situ temperature-monitoring capability under ground-simulated space conditions.It systematically investigates the effects of printing speed and structural geometry on the pre-bonding surface temperature and forming quality of truss structures in high-low temperature vacuum environments.This study reveals the mechanism by which processing and structural parameters affect the component performance through their influence on the pre-bonding surface temperature and dimensional accuracy.The experimental results show that under high-temperature vacuum conditions,the pre-bonding surface temperature is relatively high,resulting in good interfacial bonding.However,increasing the printing speed reduces the forming accuracy and leads to a decline in mechanical performance.In contrast,under low-temperature vacuum conditions,where the pre-bonding surface temperatures are lower,increasing the printing speed within a specific range effectively increases the surface temperature and bonding quality,thereby improving mechanical properties.Additionally,owing to frequent path transitions,the diagonal-strut truss exhibits a lower forming accuracy and pre-bonding surface temperature than the infilling truss,resulting in inferior mechanical performance in high-low temperature vacuum environments.展开更多
Modern industrial equipment is increasingly characterized by miniaturization,integration,and high performance,necessitating the production of complex structural parts with exceptionally high internal surface quality.D...Modern industrial equipment is increasingly characterized by miniaturization,integration,and high performance,necessitating the production of complex structural parts with exceptionally high internal surface quality.Direct manufacturing often leads to high internal surface roughness,which traditional finishing and measuring methods cannot adequately address due to the decreasing size and increasing complexity of internal structures.This is especially true for components like pipes with large aspect ratios,extremely small deep holes,multi-stage bends,cross pipes,and array holes.To meet the high-performance manufacturing demands of these parts,advanced internal surface finishing and roughness measurement technologies have gained significant attention.This review focuses on the challenges and solutions related to internal surface parts with various apertures and complex structures.Internal surface finishing methods are categorized into mechanical finishing,fluid-based finishing,and energy-field-based finishing based on their characteristics.Roughness measurement technologies are divided into tool-probing and non-probing methods.The principles,required equipment,and key parameters of each finishing and measurement approach are discussed in detail.Additionally,the advantages and limitations of these methods are summarized,and future trends are forecasted.This paper serves as a comprehensive guide for researchers and engineers aiming to enhance the internal surface quality of complex structure parts.展开更多
High-performance devices usually have curved surfaces, requiring high accuracy of shape and low surface roughness. It is a challenge to achieve high accuracies for form and position on a device with low surface roughn...High-performance devices usually have curved surfaces, requiring high accuracy of shape and low surface roughness. It is a challenge to achieve high accuracies for form and position on a device with low surface roughness. However, due to the unique nonlinear rheology, magnetorheological fluids with hard abrasives are widely applied in ultra-precision surface finishing. Compared with conventional mechanical finishing, magnetorheological finishing displays obviously advantages, such as high precision shape of machined surface, low surface roughness and subsurface damage, and easy control for finishing processes. However, finishing performance depends on various factors, e.g. volume fraction and distribution of magnetic particles, types of hard abrasives and additives, strength of magnetic field, finishing forms. Therefore, a comprehensive review on related works is essential to understand the state-of-the-art of magnetorheological finishing and beneficial to inspire researchers to develop lower cost, higher machining accuracy and efficient approaches and setups, which demonstrates a significant guidance for development of high-performance parts in fields of aerospace, navigation and clinical medicine etc. This review starts from the rheological property of magnetorheological fluids, summarizing dynamically nonlinear rheological properties and stable finishing approaches. Then, the effect of components in magnetorheological fluids is discussed on finishing performance, consisting of magnetic particles, carrier fluid, additives and abrasives. Reasonable configuration of magnetorheological fluids, and different magnetorheological finishing methods are presented for variously curved surfaces. In addition, the current finishing forms and future directions are also addressed in this review.展开更多
文摘The increasing demand for high-end equipment in crucial sectors such as aerospace,aeronautics, energy, power, information and electronics continues growing. However, the manufacturing of such advanced equipment poses significant challenges owing to high-level requirements for loading, transmission, conduction, energy conversion, and stealth. These challenges are amplified by complex structures, hard-to-cut materials, and strict standards for surface integrity and precision. To overcome these barriers in high-end equipment manufacturing, high-performance manufacturing(HPM) has emerged as an essential solution.This paper firstly discusses the key challenges in manufacturing technology and explores the essence of HPM, outlining a quantitative relationship between design and manufacturing.Subsequently, a generalized framework of HPM is proposed, accompanied by an in-depth exploration of the foundational elements and criteria. Ultimately, the feasible approaches and enabling technologies, supported by the analysis of two illustrative case studies are demonstrated. It is concluded that HPM is not just a precision and computational manufacturing framework with a core focus on multiparameter correlation in design, manufacturing, and service environments. It also represents a performance-geometry-integrated manufacturing framework for an accurate guarantee of the optimal performance.
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the financial support from the National Key Research and Development Program(No.2023YFB4606004 and No 2023YFB4606002)the Fundamental Research Funds for the Central University(No.DUT21YG116).
文摘In order to address the urgent demand for lightweight components in the aerospace,a laser-arc hybrid additive manufacturing(LAHAM)is innovatively applied to the Mg-Gd-Y-Zr alloy in this study.The results show that compared with wire arc additive manufacturing(WAAM),the grain size and texture strength of LAHAM were reduced by about 26% and 27% respectively.The β phase at grain boundaries are effectively mitigated.In LAHAM,the nanoscale β phase(Mg_(24)(Gd,Y)_(5)+Mg_(5)(Gd,Y))and β_(1) phase(Mg_(3)(Gd,Y))were uniformly distributed in the grain boundary.There were only nanoscale β phase distributed around the enriched second phase in WAAM.The size and type of nanoparticles directly affect the mechanical properties of alloys.The tensile strength and yield strength of WAAM specimen were about 228 MPa,152 MPa.Compared with WAAM,the tensile strength and yield strength of LAHAM were increased by about 12% and 15%,reaching 254 MPa and 175 MPa.The contribution of precipitation strengthening is about 42%.This study provides a new perspective for the systematic application and fabrication of Mg-Gd-Y-Zr alloy.
基金support from the National Natural Science Foundation of China(No.52175291)the Natural Science Foundation of Liaoning Province(No.2022-YGJC-22).
文摘Recently,rapid and cost-effective additive manufacturing solutions for lightweight aluminum alloys with excellent high-temperature mechanical properties have been increasingly in demand.In this study,we combined laser-arc hybrid additive manufacturing with solution and artificial aging treatments to achieve Al-Zn-Mg-Cu alloy with favorable high-temperature strength via microstructure control.Hydrogen pores became the major defect in the as-deposited and heat-treated specimens.The continuous distribution of eutectics with hard-brittle characteristics at the grain boundaries was destructed following heat treat-ment.High-densityηprecipitates were uniformly dispersed in the heat-treated Al-Zn-Mg-Cu alloy,whereas appeared coarsened and dissolved at 473 K,owing to the rapid diffusion of Zn and Mg.The average 0.2%yield strength(318±16 MPa)and ultimate tensile strength(362±20 MPa)at 473 K af-ter heat treatment were enhanced by approximately 58%and 51%,respectively,compared to those of the as-deposited specimen.In addition,theηprecipitates contributed to lattice distortions and strain fields,which prevented dislocation motion and increased slip deformation resistance at high temper-atures.The as-deposited specimen exhibited intergranular fracture at 473 K,with cracks preferring to propagate along the aggregated eutectics.However,crack propagation proceeded in the sections with more pores in the heat-treated specimen.Our approach may provide a valid option for achieving alu-minum alloys with excellent high-temperature mechanical properties.
基金Supported by National Key Research and Development Program of China(Grant No.2023YFB4603602)High-Quality Development Project(Grant No.TC220H05S-007)。
文摘Water dissolution ultraprecision continuous polishing is a nontraditional machining method specifically designed for water-soluble crystals.The aim of this study is primarily to reduce the surface roughness for small sizes from an experimental standpoint.A trajectory uniformity simulation analysis is carried out for a consistent material removal.A material removal model is developed based on the water dissolution principle and kinematic analysis.Numerical simulations of single-and multiple-water-core polishing trajectories are performed to explore the influences of the processing parameters such as movement form,number of water cores,speed ratio,polishing time,and period ratio on the material removal uniformity.The material removal rate is calculated according to the Preston equation.The trajectory density nonuniformity is utilized to evaluate the global uniformity of the trajectory distributions and optimize the processing parameters for a better material removal uniformity.Verification experiments are conducted on a large-size ultraprecision continuous polisher using a typical potassium dihydrogen phosphate(KDP)crystal with a water-soluble structure.The edge collapse is improved from 51.499μm to 1.477μm by trajectory uniformity optimization.The changing trends of line profile variations in the validation experiment and simulation are similar.An ultrasmooth surface of a 180 mm×180 mm KDP crystal with a surface roughness root mean square of 1.718 nm is obtained after water dissolution ultraprecision continuous polishing.This study provides a comprehensive method for evaluation of material removal uniformity,which is valuable for the realization of high-quality machining for water-soluble crystals.
基金co-supported by the National Key Research and Development Project of China (No. 2018YFA0703304)the National Natural Science Foundation of China (Nos. 52125504, 92148301, 52090053)。
文摘As one of the most important terminals in machining, cutting tools have been widely used for components manufacturing in aerospace and other industries. The quality of these components and processing efficiency are closely linked to the performance of cutting tools. Therefore, it is essential and critical to inspect the cutting tools and monitor the condition during the stage of manufacturing and machining. This review aims to discuss and summarize the key problems, methods,and techniques from the perspective of the tool geometric and the physical quantities measurement,including machine vision, physical sensors and data processing. It is worth mentioning that we focus on the topic of precision measurement methods and discuss universal solutions by identifying the common characteristics of the measured quantities. Eventually, the challenges and future trends for the development of in-depth research and practical applications are concluded. The research and application of precise measurement techniques for geometric and physical quantities will better promote the development of intelligent manufacturing.
基金the support of the Xingliao Talent Program of Liaoning Province(No.XLYC2001004)the High Level Talents Innovation Plan of Dalian(No.2020RD02)the Fundamental Research Funds for the Central Universities(No.DUT22LAB501).
文摘SiC_(f)/SiC ceramic matrix composites(SiC_(f)/SiC composites)are difficult to drill small holes due to their heterogeneity,high hardness,and low electrical conductivity.In order to solve the difficulties of poor quality and low efficiency when drilling small holes,a novel femtosecond laser rotary drilling(FLRD)technique is proposed.Beam kinematic paths and experimental studies were carried out to analyze the effects of processing parameters on the drilling results in the two-step drilling process.In the through-hole drilling stage,the material removal rate increases with increasing laser power,decreasing feed speed and decreasing pitch.As for the finishing stage of drilling,the exit diameter increased with increasing laser power and decreasing feed speed.The drilling parameters were selected by taking the processing efficiency of through-hole and the quality of finished hole as the constraint criteria.Holes with a diameter of 500μm were drilled using FLRD in 3 mm thick SiC_(f)/SiC composites with a drilling time<150 s.The hole aspect ratio was 6,the taper<0.2°,and there was no significant thermal damage at the orifice or the wall of the hole.The FLRD provides a solution for precision machining of small holes in difficult-to-machine materials by offering the advantages of high processing quality and short drilling times.
基金supported by the National Natural Science Foundation of China(Grant Nos.U22A20202 and 52275477).
文摘Trochoidal milling is known for its advantages in machining difficult-to-machine materials as it facilitates chip removal and tool cooling.However,the conventional trochoidal tool path presents challenges such as lower machining efficiency and longer machining time due to its time-varying cutter-workpiece engagement angle and a high percentage of non-cutting tool paths.To address these issues,this paper introduces a parameter-variant trochoidal-like(PVTR)tool path planning method for chatter-free and high-efficiency milling.This method ensures a constant engagement angle for each tool path period by adjusting the trochoidal radius and step.Initially,the nonlinear equation for the PVTR toolpath is established.Then,a segmented recurrence method is proposed to plan tool paths based on the desired engagement angle.The impact of trochoidal tool path parameters on the engagement angle is analyzed and coupled this information with the milling stability model based on spindle speed and engagement angle to determine the desired engagement angle throughout the machining process.Finally,several experimental tests are carried out using the bull-nose end mill to validate the feasibility and effectiveness of the proposed method.
基金financial support from the National Key Research and Development Program of China(2018YFA0703400)the Fundamental Research Funds for the Provincial Universities of Zhejiang(GK239909299001021)+1 种基金the Ninth China Association for Science and Technology Youth Talent Lift Project Support Plan(KYZ015324002)the Changjiang Scholars Program of Chinese Ministry of Education。
文摘Atomic surfaces are strictly required by high-performance devices of diamond.Nevertheless,diamond is the hardest material in nature,leading to the low material removal rate(MRR)and high surface roughness during machining.Noxious slurries are widely used in conventional chemical mechanical polishing(CMP),resulting in the possible pollution to the environment.Moreover,the traditional slurries normally contain more than four ingredients,causing difficulties to control the process and quality of CMP.To solve these challenges,a novel green CMP for single crystal diamond was developed,consisting of only hydrogen peroxide,diamond abrasive and Prussian blue(PB)/titania catalyst.After CMP,atomic surface is achieved with surface roughness Sa of 0.079 nm,and the MRR is 1168 nm·h^(-1).Thickness of damaged layer is merely 0.66 nm confirmed by transmission electron microscopy(TEM).X-ray photoelectron spectroscopy,electron paramagnetic resonance and TEM reveal that·OH radicals form under ultraviolet irradiation on PB/titania catalyst.The·OH radicals oxidize diamond,transforming it from monocrystalline to amorphous atomic structure,generating a soft amorphous layer.This contributes the high MRR and formation of atomic surface on diamond.The developed novel green CMP offers new insights to achieve atomic surface of diamond for potential use in their high-performance devices.
基金s supported by the National Natural Science Foundation of China(82425104)the National Key Research and Development Program of China(2022YFC3400501).
文摘Drug research and development(R&D)plays a crucial role in supporting public health.However,the traditional drug-discovery paradigm is hindered by significant drawbacks,including high costs,lengthy development timelines,high failure rates,and limited output of new drugs.Recent advances in micro/nanotechnology,along with progress in computer science,have positioned microfluidics and artificial intelligence(AI)as promising transformative tools for drug development.Microfluidics offers miniaturized,multiplexed,and versatile platforms for high-dimensional data acquisition,while AI enables the rapid processing of complex,large-scale microfluidic data;together,they are accelerating a paradigm shift in the drug-discovery process.This paper first outlines the mainstream microfluidic strategies and AI models used in drug R&D.It then summarizes and discusses real-world applications of the integrated use of these technologies across various stages of drug discovery,including early drug discovery,drug screening,drug evaluation,drug manufacturing,and drug delivery systems.Finally,the paper examines the main limitations of microfluidics and AI in drug R&D and offers an outlook on the future convergence of these technologies.
基金Supported by National Natural Science Foundation of China(Grant No.52475430)the Fundamental Research Funds for the Central Universities(Grant No.DUT23YG118).
文摘Due to the high hardness and low fracture toughness of the single crystal silicon(SCS),it is highly susceptible to microscopic cracks and subsurface damage during processing.In this paper,we propose to adjust the mechanical properties of SCS by cold plasma jet,and systematically investigate the influences of the plasma on material deformation and damage mechanisms by nanoscratch tests.The results indicate that the plasma can increase the critical normal force for the plastic-brittle(P-B)conversion of SCS.Compared with the ordinary nanoscratch test,the critical force for P-B conversion of plasma-assisted scratching at 1μm/s can increase from 43.6 to 66.4 mN.Increasing the scratching speed under ordinary conditions can enhance the plastic deformability of SCS to some extent,but its effect is not as effective as that of plasma;in addition,the increased scratching speed causes the shear bands(SBs)to lack time to propagate,so the quantity of SBs under plasma-assisted scratching at 10μm/s is reduced compared to 1μm/s.From subsurface damage topographies,the highly localized amorphous SBs cause the generation of subsurface cracks.The cold plasma can alleviate cracks on the scratched subsurface of SCS by introducing multiple SBs and stacking faults.This paper may provide a novel strategy for high-efficiency and low-damage ultra-precision machining of hard and brittle materials.
基金supported by the National Natural Science Foundation of China(Grant No.U24A20137,52475587,52103224,52405610)Science and Technology Program of Liaoning Province(2023JH1/10400044)+1 种基金Natural Science Foundation of Ningbo Municipality(2022J008)Fundamental Research Funds for the Central Universities(DUT23RC(3)051,DUT24RC(3)048)。
文摘Three-dimensional(3D)conductive structures significantly reduce flexible circuit complexity and enhance circuit integration.Direct extrusion printing technology offers the advantages of various material applicability and high flexibility for fabricating filamentary interconnects.The printing resolution is,however,highly dependent on the needle size.A micro-printing method was proposed based on fluid drawing to fabricate freestanding 3D conductive structures.The delicate structure is drawn out under the tension when printing.The printing material is a high-viscosity ink composed of silver nanoparticles(AgNPs)and polyvinylpyrrolidone(PVP).The viscosity is controlled by evaporating the ink’s solvent for drawing prints.This unique printing method utilizes a single needle,controlled by precise air pressure and speed,to construct 3D filamentary structures with varied wire widths.The 3D conductive structures exhibit superior structural retention and enhanced conductivity by thermal treatment.The drawing printing method has been successfully implemented on flexible circuits,including light-emitting diode(LED)arrays,thermal imaging displays,and multivibrator circuits.This work establishes a novel paradigm for flexible electronics manufacturing through fluid-drawing printing,achieving unprecedented customization and compatibility in fabricating 3D interconnects.
基金Supported by the Liaoning Provincial Natural Science Foundation(Grant No.2023-MSBA-008)Unveiling and Commanding Program of Liaoning Province(Grant No.2022JH1/10800080)the Fundamental Research Funds for the Central Universities(Grant No.DUT24MS008).
文摘The double-sided lapping process is extensively employed in the manufacturing of wafers,optical windows,and seal rings due to its high efficiency and ability to achieve precise flatness.However,limited research has explored the thickness uniformity among different workpieces after double-sided lapping,and the underlying mechanism remains unclear.To address the demand for higher precision,this paper first analyzed the relative kinematic model between the workpiece and the lapping plate to clarify the causes of thickness variations among workpieces after double-sided lapping.Subsequently,a finite element method(FEM)model was developed to account for the pressure distribution on the workpiece surfaces at the initial stage of the process.The results indicate that the number of workpieces influences the final thickness variation.Then,various sets of thin copper plates with different thicknesses were lapped,and the findings revealed that five copper plates processed simultaneously exhibited more uniform thickness compared to the three plates.The experimental results align well with the theoretical analysis.Ultimately,a thickness variation of less than 6μm was achieved on five copper plates measuringΦ100×2.9 mm.This study presents a comprehensive analysis of the mechanisms influencing thickness uniformity in the double-sided lapping process and provides practical guidelines for optimizing the process to achieve stringent precision standards in industrial applications.
基金supported by the National Key R&D Program of China(2022YFB4602401)the National Natural Science Foundation of China(52475294,52075071)+1 种基金the State Key Laboratory of High-performance Precision Manufacturing(ZY202404)the Fundamental Research Funds for the Central Universities(DUT24YG133).
文摘Marine biofouling is the undesired attachment and formation of marine organisms on surfaces,which adversely affects ship maintenance,economic costs,and ecosystem health.Despite remarkable advancements in antifouling coatings,developing formulations that simultaneously achieve environmental benign and high antifouling performances remains a critical challenge.Herein,drawing inspiration from the natural antifouling mechanisms including the superhydrophobicity of lotus leaves and biochemical defense of coral mucus,we developed a Superhydrophobic Antifouling Coating(SHAC)incorporating coral mucus-derived agents.This biomimetic design synergistically integrates physical anti-adhesion of superhydrophobic surfaces with chemical repellency of antifouling agents,yielding outstanding antifouling performance.The SHAC demonstrates remarkable durability(withstanding 100 abrasion cycles),sustained superhydrophobicity(contact angle>150°),and outstanding antifouling efficacy(92%bacterial and 96%algal inhibition).Marine field tests demonstrate significant reduction in fouling organism attachment over 30 days.Our work presents an eco-friendly and high-performance solution to marine biofouling,bridging the gap between sustainability and effectiveness in antifouling technology.
基金supported by the National Natural Science Foundation of China(Grant No.U22A20202)。
文摘Thin-walled parts have been widely employed as critical components in high-performance equipment due to the high specific strength and light weight.However,owing to their relatively weak rigidity and poor damping properties,chatter vibration is likely to occur during the milling process,which severely deteriorates surface quality and decreases machining productivity.Therefore,chatter suppression is essential for improving the dynamic machinability of thin-walled structures and has attracted extensive attention over the past few decades.This paper reviews the current state of the art in research concerning chatter suppression during the milling of thin-walled workpieces.In consideration of the dynamic characteristics of this process,the challenges in design and application of chatter attenuation methods are highlighted.Moreover,various chatter suppression techniques,involving passive,active,and semi-active methods,are comprehensively discussed in terms of basic concepts,working mechanism,optimal design,and application.Finally,future research opportunities in chatter mitigation technology for thin-wall milling are recommended.
基金supported by National Natural Science Foundation of China(Grant No.52375312)National Key Research and Development Program of China(Grant No.2023YFB4605900)+3 种基金Liaoning Province Science and Technology Plan Joint Program(Grant No.2023JH2/101700299)Open Research Fund of Key Laboratory of Precision Special Machining and Micromanufacturing Technology of Ministry of Education for Dalian University of Technology(Grant No.B202305)Shenzhen National Major Science and Technology Projects(Grant No.CJGJZD20240729113704006)Shenzhen Key Technology R&D Programs(Grant No.JSGG20210420091802007).
文摘Laser-directed energy deposition(LDED)technology has demonstrated great potential for the rapid and integrated fabrication of nickel-based superalloy components.The plastic deformation-assisted method is crucial for achieving grain refinement and microstructural homogeneity in LDED-fabricated superalloys.However,existing methods suffer from uniformity constraints owing to their high deformation resistance,which significantly limits their application in load-bearing components.To address these issues,a synchronous-hot-forging-assisted(SHFA)LDED additive manufacturing method was proposed,and its effects on the macroscopic morphology,microstructure,and mechanical properties of GH4169 nickel-based alloy specimens were systematically compared.The results demonstrated up to 30.1%average plastic deformation in hot-forging components while maintaining good surface flatness.The synergistic effect of dislocation accumulation and dynamic recrystallization during hot forging enables dramatic grain refinement,reducing the average grain size by 89.1%(from 168.5μm to 18.4μm)while weakening texture intensity from 15.31 to 2.15,ultimately promoting equiaxed grain formation.The pores of hot-forging components changed from fine round to flat,the porosity decreased from 0.264%to 0.089%,and the densification level was significantly improved.With the increase in the synchronous hot-forging force,the average ultimate tensile strength of hot-forging components can reach 1175.1 MPa,while the anisotropy difference is gradually weakened.The SHFA-LDED process not only achieves excellent grain refinement and microstructure homogenization but also enhances mechanical properties,providing a new technical path for the additive manufacturing of high-performance nickel-based superalloy components.
基金the National Natural Science Foundation of China(Award No.07120016)support by the Dalian University of Technology(DUT)(Award Nos.82232022,82232043,and DUT22LAB404)AVIC Shenyang Aircraft Company(Award No.12020641 and 12020642)。
文摘Leveraging surface texturing to realize significant friction reduction at contact interfaces has emerged as a preferred technique among tribology experts,boosting tribological energy efficiency and sustainability.This review systematically demonstrates optimization strategies,advanced manufacturing methods,typical applications,and outlooks of technical challenges toward surface texturing for friction reduction.Firstly,the lubricated contact models of microtextures are introduced.Then,we provide a framework of state-of-the-art research on synergistic friction optimization strategies of microtexture structures,surface treatments,liquid lubricants,and external energy fields.A comparative analysis evaluates the strengths and weaknesses of manufacturing techniques commonly employed for microtextured surfaces.The latest research advancements in microtextures in different application scenarios are highlighted.Finally,the challenges and directions of future research on surface texturing technology are briefly addressed.This review aims to elaborate on the worldwide progress in the optimization,manufacturing,and application of microtexture-enabled friction reduction technologies to promote their practical utilizations.
基金supported by National Key Research and Development Program of China(Grant No.2023YFB4605301)the National Natural Science Foundation of China(Grant No.52130506)。
文摘The z-axis-inclined 3D printing process using short carbon fiber-reinforced thermoplastic composites offers the potential for the support-free fabrication of complex structures and theoretically unlimited extension of printed components.It has emerged as a promising approach for in-orbit manufacturing of high-performance thermoplastic composite truss structures.However,extreme conditions of the space environment,such as high vacuum and fluctuating high-low temperatures,significantly alter the heat-transfer behavior during the printing process,often resulting in dimensional inaccuracies and degraded mechanical performance.Existing process optimization strategies fail to account for the coupled effects of vacuum and thermal extremes,limiting their applicability in guiding process design under varying vacuum temperature conditions.To address this gap,this study establishes a truss3D printing experimental platform with in situ temperature-monitoring capability under ground-simulated space conditions.It systematically investigates the effects of printing speed and structural geometry on the pre-bonding surface temperature and forming quality of truss structures in high-low temperature vacuum environments.This study reveals the mechanism by which processing and structural parameters affect the component performance through their influence on the pre-bonding surface temperature and dimensional accuracy.The experimental results show that under high-temperature vacuum conditions,the pre-bonding surface temperature is relatively high,resulting in good interfacial bonding.However,increasing the printing speed reduces the forming accuracy and leads to a decline in mechanical performance.In contrast,under low-temperature vacuum conditions,where the pre-bonding surface temperatures are lower,increasing the printing speed within a specific range effectively increases the surface temperature and bonding quality,thereby improving mechanical properties.Additionally,owing to frequent path transitions,the diagonal-strut truss exhibits a lower forming accuracy and pre-bonding surface temperature than the infilling truss,resulting in inferior mechanical performance in high-low temperature vacuum environments.
基金the financial supports from National Key R&D Program of China(No.2022YFB3403301)the Funds for International Cooperation and Exchange of the National Natural Science Foundation of China(No.52311530080)。
文摘Modern industrial equipment is increasingly characterized by miniaturization,integration,and high performance,necessitating the production of complex structural parts with exceptionally high internal surface quality.Direct manufacturing often leads to high internal surface roughness,which traditional finishing and measuring methods cannot adequately address due to the decreasing size and increasing complexity of internal structures.This is especially true for components like pipes with large aspect ratios,extremely small deep holes,multi-stage bends,cross pipes,and array holes.To meet the high-performance manufacturing demands of these parts,advanced internal surface finishing and roughness measurement technologies have gained significant attention.This review focuses on the challenges and solutions related to internal surface parts with various apertures and complex structures.Internal surface finishing methods are categorized into mechanical finishing,fluid-based finishing,and energy-field-based finishing based on their characteristics.Roughness measurement technologies are divided into tool-probing and non-probing methods.The principles,required equipment,and key parameters of each finishing and measurement approach are discussed in detail.Additionally,the advantages and limitations of these methods are summarized,and future trends are forecasted.This paper serves as a comprehensive guide for researchers and engineers aiming to enhance the internal surface quality of complex structure parts.
基金funded by the National Key Research and Development Program of China (2018YFA0703400)the Young Scientists Fund of the National Natural Science Foundation of China (52205447)+2 种基金Changjiang Scholars Program of Chinese Ministry of Educationthe Xinghai Science Funds for Distinguished Young Scholars at Dalian University of Technologythe Collaborative Innovation Center of Major Machine Manufacturing in Liaoning。
文摘High-performance devices usually have curved surfaces, requiring high accuracy of shape and low surface roughness. It is a challenge to achieve high accuracies for form and position on a device with low surface roughness. However, due to the unique nonlinear rheology, magnetorheological fluids with hard abrasives are widely applied in ultra-precision surface finishing. Compared with conventional mechanical finishing, magnetorheological finishing displays obviously advantages, such as high precision shape of machined surface, low surface roughness and subsurface damage, and easy control for finishing processes. However, finishing performance depends on various factors, e.g. volume fraction and distribution of magnetic particles, types of hard abrasives and additives, strength of magnetic field, finishing forms. Therefore, a comprehensive review on related works is essential to understand the state-of-the-art of magnetorheological finishing and beneficial to inspire researchers to develop lower cost, higher machining accuracy and efficient approaches and setups, which demonstrates a significant guidance for development of high-performance parts in fields of aerospace, navigation and clinical medicine etc. This review starts from the rheological property of magnetorheological fluids, summarizing dynamically nonlinear rheological properties and stable finishing approaches. Then, the effect of components in magnetorheological fluids is discussed on finishing performance, consisting of magnetic particles, carrier fluid, additives and abrasives. Reasonable configuration of magnetorheological fluids, and different magnetorheological finishing methods are presented for variously curved surfaces. In addition, the current finishing forms and future directions are also addressed in this review.
