International Journal of Machine Tools & Manufacture最新文献

{"title":"Towards understanding the polishing behavior of thin anisotropic crystals: Coupling, discrepancy, and control across scales","authors":"Wei Gao ,&nbsp;Caoyang Xue ,&nbsp;Qi Sun ,&nbsp;Fang Han ,&nbsp;Bing-Feng Ju ,&nbsp;Li-tian Xuan ,&nbsp;Junjie Zhang ,&nbsp;Wule Zhu","doi":"10.1016/j.ijmachtools.2025.104269","DOIUrl":"10.1016/j.ijmachtools.2025.104269","url":null,"abstract":"<div><div>Thin anisotropic crystals (TACs) have potential applications in semiconductors, microelectronics, and aerospace. However, polishing a TAC workpiece with a compliant tool is highly challenging because of its susceptibility to deformation and brittle damage owing to its thin structure. Another significant challenge for polishing is the anisotropic discrepancy, which is highly dependent on the crystal planes/directions. To address these challenges and ultimately realize the process control of polishing a TAC workpiece, this study establishes a comprehensive multiscale modeling framework. The proposed framework analytically incorporates the macroscale tool–TAC interaction mechanics, macro/micro coupling material removal mechanism, and macro/micro coupling subsurface damage behavior according to the physical properties of a TAC workpiece. Experiments at different scales are conducted to validate notable discrepancies in the surface and subsurface material responses in the polishing of a TAC workpiece, agreeing well with analytical predictions. Based on the cross-scale study and framework, space- and time-domain control strategies are proposed, demonstrating the capability for effectively eliminating the anisotropic discrepancy from macro- to microscale and enabling deterministic control in the polishing of TACs.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"207 ","pages":"Article 104269"},"PeriodicalIF":14.0,"publicationDate":"2025-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143739024","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Defects in metal-forming: Formation mechanism, prediction and avoidance","authors":"Jun Ma ,&nbsp;Xuefeng Tang ,&nbsp;Yong Hou ,&nbsp;Heng Li ,&nbsp;Jianguo Lin ,&nbsp;M.W. Fu","doi":"10.1016/j.ijmachtools.2025.104268","DOIUrl":"10.1016/j.ijmachtools.2025.104268","url":null,"abstract":"<div><div>Defects in metal-forming create numerous bottleneck issues related to product quality, properties and performance, productivity, production cost, and sustainability. Effectively addressing defect issues in the up-front design process via prediction and avoidance of defect formation is the most critical and challenging issue in metal-forming based product development. In this paper, vital insights into defect classification, formation mechanisms, modelling/prediction, and avoidance principles and strategies in metal-forming are orchestrated and articulated. First, almost all the potential defects in metal-forming are exemplified and classified into three categories, viz., stress-induced, flow-induced, and microstructure-related defects. For each defect category, its influencing factors, formation mechanisms, and analysis approaches are delineated. Additionally, the countermeasures are articulated from the aspects of defect identification, control, avoidance or elimination by employing different state-of-the-art techniques, including in-process sensing/monitoring/detection, data-based modelling and online adaptive control. Finally, perspective insights into defect analysis, modelling/prediction, and avoidance are orchestrated and presented, focusing on innovative process developments, real-time in-process monitoring, physics-informed and data-driven through-process modelling, and strategies for intelligent and sustainable manufacturing.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"207 ","pages":"Article 104268"},"PeriodicalIF":14.0,"publicationDate":"2025-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143724294","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Particle floating and transfer effect in cored wire arc additive manufacturing: Formation mechanism and laser shock inhibition","authors":"Le Jia,&nbsp;Hao Yi,&nbsp;Furui Jiao,&nbsp;Huajun Cao","doi":"10.1016/j.ijmachtools.2025.104260","DOIUrl":"10.1016/j.ijmachtools.2025.104260","url":null,"abstract":"<div><div>Multi-material wire arc additive manufacturing (WAAM) presents a promising approach for fabricating high-end equipment components, with cored wire arc additive manufacturing (CWAAM) attracting significant interest. However, uneven particle distribution in CWAAM impedes technological advancement, as the mechanisms of particle flotation and its suppression remain unexplored. To address this issue, a novel nickel alloy cored wire incorporating TiC particles was developed, and the mechanism of particle flotation was investigated for the first time. The results indicate that the cored wire exhibits excellent formability, with particle flotation attributed to unstable droplet transfer, particle overflow along the side seam, and density differences. Furthermore, a laser shock-assisted CWAAM method was introduced to suppress particle flotation. Laser shock generated shock waves in the molten pool, inducing significant oscillations. Shock wave propagation altered molten pool flow dynamics and particle motion, effectively suppressing particle flotation and mitigating defects. This resulted in uniform particle dispersion in the deposited layer and facilitated particle size reduction. Additionally, laser shock eliminated porosity and fusion defects caused by particle flotation. The average grain size of the deposition layer decreased by 34.5 % and 23.3 % compared to solid wire arc additive manufacturing (SWAAM) and CWAAM, respectively, with a more random grain orientation. The average microhardness reached 394.8 HV_0.3, exceeding that of the other two methods, with no significant distribution differences. Yield strength, ultimate tensile strength, and elongation increased by 7.71 %, 5.37 %, and 12.71 % in the horizontal direction, and by 18.62 %, 6.63 %, and 13.03 % in the longitudinal direction, respectively, compared to conditions without laser shock, effectively reducing performance anisotropy. This innovative laser shock-assisted CWAAM method effectively mitigates weakened reinforcement effects and defects caused by particle flotation, thereby advancing WAAM toward large-scale, multi-material, and high-performance manufacturing.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"207 ","pages":"Article 104260"},"PeriodicalIF":14.0,"publicationDate":"2025-03-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143610192","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Stable tongues induced by milling tool runout","authors":"David Hajdu ,&nbsp;Oier Franco ,&nbsp;Markel Sanz-Calle ,&nbsp;Giovanni Totis ,&nbsp;Jokin Munoa ,&nbsp;Gabor Stepan ,&nbsp;Zoltan Dombovari","doi":"10.1016/j.ijmachtools.2025.104258","DOIUrl":"10.1016/j.ijmachtools.2025.104258","url":null,"abstract":"<div><div>High material removal rates and performances are required for modern milling operations, which may trigger self-excited chatter vibrations. Such undesired vibrations cause unacceptable machined surface quality and premature deterioration of the cutting tool. After many decades of research and successful industrial solutions to this problem, some unexpected phenomena still arise, which put in doubt the effectiveness of well-known chatter theories and of the associated predictive numerical methods. Specifically, runout is a typically ignored consequence of inaccurate fixing of the tool, which has essential impact on the actual cutter-workpiece engagement and on the machined surface quality. The unequal engagement of cutter teeth change the dynamical behavior radically and prevent the application of classical simplifications in the modeling of milling processes. Moreover, in addition to the kinematically different teeth cycle-paths, the coexisting forced vibrations induce early fly-over effects of cutting edges creating new stability boundaries close to the resonant oscillations. This paper presents the underlying principles of this experienced phenomenon related to tool runout and its stabilization effect on chatter vibrations. Focusing on conventional milling cutters, the paper breaks with the widely held assumption that forced vibration has negligible effect on stability in the presence of tool runout. Initial laboratory experiments validate this tool irregularity induced phenomenon and industrial tests demonstrate the technical relevance of the results.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"206 ","pages":"Article 104258"},"PeriodicalIF":14.0,"publicationDate":"2025-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143548738","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Optimized dispersion of inorganic metal salts in photocurable resins for high-precision continuous 3D printing of complex metal structures","authors":"Dylan Joralmon,&nbsp;John Walling,&nbsp;Amal Rai,&nbsp;Xiangjia Li","doi":"10.1016/j.ijmachtools.2025.104259","DOIUrl":"10.1016/j.ijmachtools.2025.104259","url":null,"abstract":"<div><div>Emerging metal additive manufacturing (AM) technologies that incorporate metal precursors to fabricate both metal and alloy 3D objects has become an attractive method for producing complex metallic objects with microscale features. However, current metal precursor additive manufacturing technologies that operate in a layer-by-layer manner are limited by low solid loading, poor rheological performance, slow printing speed, and anisotropic physical properties from the stacking of individual layers. To circumvent these challenges, printing resin with high solid loading of metal precursors and excellent rheological behavior was developed and employed in a rapid, layer-less additive manufacturing process to fabricate metal precursor objects within minutes. Addition of BYK-2013 dispersant, an ionic copolymer, to aid in the homogeneous dispersion of metal salt precursor dispersion was able to achieve a high maximum copper precursor concentration of 60 % (w/w) while sustaining stable dispersion for more than 24 h without displaying significant particle sedimentation greater than 1 mm. Cross-linking characteristics were investigated to optimize surface quality and reduce printing times of 3D printed objects resulting in low surface roughness (0.986 μm) and printing speeds upwards of 20 μm s⁻¹. Additionally, experimental results indicated that resins containing BYK-2013 exhibited superior hydrophobicity with no rehydration of inorganic metal salts after 180 min while maintaining an excellent viscosity of approximately 0.16 Pa s. Thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC) guided post-processing optimization was successfully conducted to promote stable thermal decomposition during the removal of organics, metal oxide formation, and metal oxide reduction leading to highly robust copper lattices with final concentration of copper upwards of 92.8 % and an overall average isotropic shrinkage of 62 %. Furthermore, the microstructure evinces that an either dense or porous microstructure can be realized by adjusting metal precursor concentration to generate tunable physical properties with the final copper part. This study provides a unique and cost-effective methodology for formulating photocurable metal precursor resins with exemplary rheological behavior to produce intricately designed metal and alloys for a wide range of industrial engineering applications.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"206 ","pages":"Article 104259"},"PeriodicalIF":14.0,"publicationDate":"2025-02-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143465141","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A novel continuous dynamic recrystallization model to reveal grain refinement mechanism in constraining ring rolling of thin-walled conical structure with inner ribs","authors":"Fei Chen ,&nbsp;Xiao Tian ,&nbsp;Zixuan Liu ,&nbsp;Dongsheng Qian ,&nbsp;Xinghui Han ,&nbsp;Bing Wang ,&nbsp;He Wang ,&nbsp;Zhenshan Cui","doi":"10.1016/j.ijmachtools.2025.104255","DOIUrl":"10.1016/j.ijmachtools.2025.104255","url":null,"abstract":"<div><div>Constraining ring rolling (CRR) is an integral and near net-shape forming approach to fabricate the seamless ring aluminum components in aerospace field. The service property of the formed ring components mainly depends on the microscopical grain texture. However, investigation and modeling of microstructure evolution in this complex hot working processes are not appropriately performed, which hinders further control of the forming quality of components during CRR. In this study, by analyzing the characteristics of CRR process and deformation modes in different characteristic zones of typical thin-walled conical ring with inner transverse ribs (TWCRITRs), a continuous dynamic recrystallization (CDRX) model of aluminum alloy that considers the influence of thermal deformation history was firstly proposed. The developed CDRX model was integrated into the finite element (FE) to predict microstructure evolution throughout the entire hot working process. The optimal parameters of the CRR process were obtained with the uniformity and fineness of microstructure as the goal, guiding the subsequent forming experiment. The predicted shape and microstructure agree well with the experimental results. It is found that the grain refinement mechanisms of 2A14 Al-alloy TWCRITRs during CRR include CDRX and thin grain cutting CDRX. Due to the low-angle grain boundaries (LAGBs) being pinned by the upper and lower high-angle grain boundaries (HAGBs), the recrystallization efficiency in the thin grain cutting CDRX is higher than that in the traditional CDRX mechanism. The shear deformation at thin-wall and complex deformation at the corner promotes the occurrence of thin grain cutting CDRX mechanism with a higher recrystallization efficiency. Eventually, the mechanical properties of manufacturing TWCRITRs met the requirements. All of these provide additional insights into the shape and microstructure controlled CRR process for TWCRITRs.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"206 ","pages":"Article 104255"},"PeriodicalIF":14.0,"publicationDate":"2025-02-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143421036","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Covalently armoring graphene on diamond abrasives with unprecedented wear resistance and abrasive performance","authors":"Qiang Lin ,&nbsp;Sulin Chen ,&nbsp;Hongbin Li ,&nbsp;Zhengzong Sun ,&nbsp;Zhinan Zhang ,&nbsp;Martin Dienwiebel ,&nbsp;Michael Moseler ,&nbsp;Bin Shen","doi":"10.1016/j.ijmachtools.2025.104254","DOIUrl":"10.1016/j.ijmachtools.2025.104254","url":null,"abstract":"<div><div>Next-generation semiconductor materials, including diamond, SiC, and GaN, offer significant advantages for high-power devices. However, the high-performance polishing of these ultrahard materials is limited by insufficient grit wear resistance and low-quality material removal with conventional diamond abrasives. In this study, we report robust integration of flexible graphene armor on diamond abrasives through covalent interfacial bonding for high-efficiency high-quality polishing of ultrahard materials. Utilizing a novel Ga-diamond cellular wetting strategy followed by vacuum heating treatment, we achieved highly scalable production of graphene-armored diamond abrasives with a productivity of 1 kg/L. The employment of graphene-armored diamond abrasives simultaneously improved the polishing efficiency and polishing quality, enabling damage-free atomic-level surface finish and an atomic attrition rate 5 times greater than conventional diamond abrasives. This efficient material attrition is attributed to the robust combination of exceptional intrinsic wear resistance, bonding capability and high flexibility of graphene with the ultrahigh hardness of diamond. The synergy of soft graphene and hard diamond grit provides sufficient material removal capability while simultaneously reducing the polishing damage that is often induced by brittle fracture and extreme local contact pressure with conventional diamond abrasives. This work offers a novel solution that enables high-efficiency high-quality polishing of ultrahard materials with a room-temperature, chemical-free and low-cost mechanical polishing procedure.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"206 ","pages":"Article 104254"},"PeriodicalIF":14.0,"publicationDate":"2025-02-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143348737","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Micro-zone cutting temperature measurement using a nitrogen-extracted boron and hydrogen co-doped diamond tool for ultra-precision machining","authors":"Shiquan Liu,&nbsp;Liang An,&nbsp;Hui Li,&nbsp;Kaiyang Xia,&nbsp;Mao Peng,&nbsp;Zhongwei Li,&nbsp;Bing-Feng Ju,&nbsp;Yuan-Liu Chen","doi":"10.1016/j.ijmachtools.2024.104244","DOIUrl":"10.1016/j.ijmachtools.2024.104244","url":null,"abstract":"<div><div>Accurate measurement of the cutting temperature is essential for monitoring the cutting state and ensuring a reliable cutting process. In ultra-precision machining, directly measuring the temperature in the micro/nano-scale cutting zones poses substantial challenges. In this study, a nitrogen-extracted boron and hydrogen co-doped diamond tool was proposed. By transitioning into a p-type semiconductor, the diamond tool manifests heat-sensitive characteristics, enabling to sense the cutting temperature. The inherent orientation-dependent behaviour of boron doping in diamond tools, particularly notable in the (100) orientation, was suppressed through removal of nitrogen from the lattice. The lattice distortions induced by heavy boron doping after nitrogen removal in (111)-oriented diamond were significantly mitigated by co-doping with boron and hydrogen. This approach enhanced the crystal quality and semiconductor electrical properties of the diamond tools, which are crucial for accurate measurement of the cutting temperature. Compared with boron-doped diamond tools, the nitrogen-extracted boron and hydrogen co-doped diamond tool exhibited superior sensitivity and an extended range of temperature sensing. The diamond tool was employed for cutting temperature measurements during the micro-scale depth-graded turning of copper and titanium alloys, as well as the nano-scale progressive scratching of silicon. Experiments demonstrated the tool's capabilities for in-process monitoring of cutting states in micro zones, along with high-sensitivity detection of micro/nano-scale surface morphologies and characteristics during ultra-precision machining. The innovation of temperature-sensing diamond tools not only achieves accurate measurement of temperature in micro/nano-scale cutting zones during ultra-precision machining, but also provides an effective approach for in-process state characterisation for advanced manufacturing.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"205 ","pages":"Article 104244"},"PeriodicalIF":14.0,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142929192","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Laser additive manufacturing of multimaterials with hierarchical interlocking interface via a flexible scraper-based method","authors":"Linqing Liu ,&nbsp;Di Wang ,&nbsp;Tianyu Wang ,&nbsp;Changjun Han ,&nbsp;Yang Li ,&nbsp;Hua Tan ,&nbsp;Wei Zhou ,&nbsp;Xingchen Yan ,&nbsp;Liming Lei ,&nbsp;Yongqiang Yang","doi":"10.1016/j.ijmachtools.2024.104236","DOIUrl":"10.1016/j.ijmachtools.2024.104236","url":null,"abstract":"<div><div>Superalloy/copper structures are promising for application in rocket combustion chambers and can integrate the high strength of superalloys and the high thermal conductivity of copper in a single component to improve performance and work efficiency. The natural hierarchical interlocking structure can provide inspiration for the interface design of metallic multimaterial structures to resolve or minimise the critical issue of interfacial bonding reliability arising from the distinct physical properties of materials (thermal expansivity, thermal conductivity, <em>etc.</em>). In this study, IN718/CuCrZr multimaterial structures with hierarchical interlocking interfaces were designed and manufactured using laser powder bed fusion (LPBF) via a flexible scraper-based method. The evolution of microstructure at the interface and mechanical properties were investigated. The thermomechanical behaviour during the LPBF process, interfacial bonding mechanisms, and deformation mechanisms were discussed. Compared to printing CuCrZr before IN718, printing IN718 before CuCrZr was a promising printing sequence for reducing the stress concentration and lack-of-fusion defects, and promoting material intermixing at the interface. A hierarchical interlocking interface design can promote material intermixing and grain refinement at the interface. In addition, the hierarchical interlocking interface design can improve the stress distribution and deflect the fracture path at the interface, which helps increase energy dissipation and enhance interfacial bonding. Three-point flexural test results show that the ultimate flexural strength of the N1 samples was increased by 15 % compared to the N0 samples. This study demonstrates the feasibility of changing the interfacial stress distribution and deformation behaviour of LPBF-processed metallic multimaterial parts through a hierarchical interlocking interface design, which may provide new ideas and methods for the development of multimaterial parts with high interfacial bonding strength and reliability.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"205 ","pages":"Article 104236"},"PeriodicalIF":14.0,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142793449","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Electrical discharge-mechanical hybrid drilling of micro-holes in carbon fibre-reinforced polymers","authors":"Yijin Zhao,&nbsp;Xiaodong Yang,&nbsp;Yong Lu,&nbsp;Xiaoming Duan","doi":"10.1016/j.ijmachtools.2024.104243","DOIUrl":"10.1016/j.ijmachtools.2024.104243","url":null,"abstract":"<div><div>The machining of deep micro-holes in carbon fibre-reinforced polymers (CFRP) components exhibits a significantly increased demand in the industry. However, it is difficult to machine CFRP deep micro-holes using conventional mechanical drilling and non-conventional processes individually because of the anisotropic and inhomogeneous characteristics of CFRP. To address this problem, an electrical discharge-mechanical hybrid drilling method was proposed in this study. In this method, a specialized servo control strategy was employed to effectively utilize the electrical discharge machining and mechanical drilling, based on the distinct difference in electrical conductivity between the carbon fibre and the resin in CFRP. This effectively resolved the challenges posed by the high hardness of the carbon fibre for mechanical drilling and the non-conductivity of the resin for EDM, taking advantage of both EDM and mechanical drilling. High-speed photography, processing debris analysis, discharge state monitoring, and finite element simulation were performed to investigate the machining process and material removal mechanism of electrical discharge-mechanical hybrid drilling. The results showed that most of the carbon fibre and resin were individually removed by EDM and mechanical drilling, respectively. However, in the interfacial region between the carbon fibre and resin, both mechanical drilling and EDM occur simultaneously. The heat generated during the EDM of carbon fibre also leads to the thermal decomposition and vaporization of the resin in proximity to the carbon fibre. Furthermore, deep micro-holes machining with a diameter of 330 μm and a depth-to-diameter ratio of 15.1 was performed on CFRP component to validate the advantages of the proposed hybrid drilling method. Compared with EDM, the proposed hybrid drilling method exhibited a 29.1 % increase in efficiency, 56.25 % reduction in taper, and 54.32 % reduction in the heat-affected zone. These outcomes demonstrate that the electrical discharge-mechanical hybrid drilling holds great potential for machining high-quality micro-holes on advanced multilayer composites with anisotropic and inhomogeneous properties.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"205 ","pages":"Article 104243"},"PeriodicalIF":14.0,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142901911","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}