Pub Date : 2025-03-01DOI: 10.1016/j.ijmachtools.2025.104258
David Hajdu , Oier Franco , Markel Sanz-Calle , Giovanni Totis , Jokin Munoa , Gabor Stepan , Zoltan Dombovari
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.
{"title":"Stable tongues induced by milling tool runout","authors":"David Hajdu , Oier Franco , Markel Sanz-Calle , Giovanni Totis , Jokin Munoa , Gabor Stepan , 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}
Pub Date : 2025-02-19DOI: 10.1016/j.ijmachtools.2025.104259
Dylan Joralmon, John Walling, Amal Rai, Xiangjia Li
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.
{"title":"Optimized dispersion of inorganic metal salts in photocurable resins for high-precision continuous 3D printing of complex metal structures","authors":"Dylan Joralmon, John Walling, Amal Rai, 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<sup>−1</sup>. 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}
Pub Date : 2025-02-07DOI: 10.1016/j.ijmachtools.2025.104255
Fei Chen , Xiao Tian , Zixuan Liu , Dongsheng Qian , Xinghui Han , Bing Wang , He Wang , Zhenshan Cui
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.
{"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 , Xiao Tian , Zixuan Liu , Dongsheng Qian , Xinghui Han , Bing Wang , He Wang , 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}
Pub Date : 2025-02-03DOI: 10.1016/j.ijmachtools.2025.104254
Qiang Lin , Sulin Chen , Hongbin Li , Zhengzong Sun , Zhinan Zhang , Martin Dienwiebel , Michael Moseler , Bin Shen
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.
{"title":"Covalently armoring graphene on diamond abrasives with unprecedented wear resistance and abrasive performance","authors":"Qiang Lin , Sulin Chen , Hongbin Li , Zhengzong Sun , Zhinan Zhang , Martin Dienwiebel , Michael Moseler , 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}
Pub Date : 2025-02-01DOI: 10.1016/j.ijmachtools.2024.104244
Shiquan Liu, Liang An, Hui Li, Kaiyang Xia, Mao Peng, Zhongwei Li, Bing-Feng Ju, Yuan-Liu Chen
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.
{"title":"Micro-zone cutting temperature measurement using a nitrogen-extracted boron and hydrogen co-doped diamond tool for ultra-precision machining","authors":"Shiquan Liu, Liang An, Hui Li, Kaiyang Xia, Mao Peng, Zhongwei Li, Bing-Feng Ju, 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}
Pub Date : 2025-02-01DOI: 10.1016/j.ijmachtools.2024.104236
Linqing Liu , Di Wang , Tianyu Wang , Changjun Han , Yang Li , Hua Tan , Wei Zhou , Xingchen Yan , Liming Lei , Yongqiang Yang
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, etc.). 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.
{"title":"Laser additive manufacturing of multimaterials with hierarchical interlocking interface via a flexible scraper-based method","authors":"Linqing Liu , Di Wang , Tianyu Wang , Changjun Han , Yang Li , Hua Tan , Wei Zhou , Xingchen Yan , Liming Lei , 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}
Pub Date : 2025-02-01DOI: 10.1016/j.ijmachtools.2024.104243
Yijin Zhao, Xiaodong Yang, Yong Lu, Xiaoming Duan
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.
{"title":"Electrical discharge-mechanical hybrid drilling of micro-holes in carbon fibre-reinforced polymers","authors":"Yijin Zhao, Xiaodong Yang, Yong Lu, 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}
Pub Date : 2025-02-01DOI: 10.1016/j.ijmachtools.2024.104245
Liyu Wang , Xiaoxing Gao , Qiaosheng Feng , Xinlong Guo , Zhen Li , Wenzhao An , Weiwei Xu , Qilin Li , Songmei Yuan
Continuous silicon carbide (SiC) fibre-reinforced titanium (Ti) matrix composites (SiCf/Ti) possess exceptional properties, making them promising for aerospace applications. Continuous SiC fibres significantly enhance the axial tensile strength of SiCf/Ti compared to traditional Ti alloys. To utilise this material fully, its axial dimensions are fixed during manufacturing, but the outer Ti matrix layer must be thinned to meet structural accuracy requirements. Thinning often leads to interfacial cracking and fibre breakage owing to machining stress, which presents a major challenge in manufacturing. The deformation mechanism during thinning is unclear and the lack of low-stress thinning methods significantly limits the potential applications of SiCf/Ti. This study investigates the macroscopic deformation and microstructural evolution of SiCf/Ti under ultrasonic cutting (UC) through orthogonal experiments. Compared with conventional cutting (CC), UC reduces cutting force by 20 % and surface residual stress by 60 %, while increasing subsurface residual stress and nano-hardness. The acoustic softening effect in UC reduces cutting force and surface stress, while high-frequency stress waves elevate subsurface stress. Digital image correlation (DIC) analysis reveals that the combined effects of loading and unloading cycles during UC produce an elastic recovery strain, reducing the overall deformation in SiCf/Ti during machining. Additionally, UC promotes grain refinement in the outer Ti layer of SiCf/Ti and induces a stress concentration at the α-Ti and β-Ti interface, facilitating the transformation of α-Ti to β-Ti. The presence of SiC fibres amplifies the effects of the ultrasonic energy, accelerating dislocation diffusion and annihilation, promoting dynamic recrystallisation, and reducing the dislocation density between the fibres. Moreover, UC homogenises and realigns the stress field at the SiCf/Ti interface, making the composition and structure of the interface more uniform and reducing interfacial damage. This study provides theoretical and practical insights into low-stress thinning, paving the way for broader applications of SiCf/Ti in advanced structural components.
{"title":"How does ultrasonic cutting affect the macroscopic deformation and microstructure evolution of fibre-reinforced titanium matrix composites?","authors":"Liyu Wang , Xiaoxing Gao , Qiaosheng Feng , Xinlong Guo , Zhen Li , Wenzhao An , Weiwei Xu , Qilin Li , Songmei Yuan","doi":"10.1016/j.ijmachtools.2024.104245","DOIUrl":"10.1016/j.ijmachtools.2024.104245","url":null,"abstract":"<div><div>Continuous silicon carbide (SiC) fibre-reinforced titanium (Ti) matrix composites (SiC<sub>f</sub>/Ti) possess exceptional properties, making them promising for aerospace applications. Continuous SiC fibres significantly enhance the axial tensile strength of SiC<sub>f</sub>/Ti compared to traditional Ti alloys. To utilise this material fully, its axial dimensions are fixed during manufacturing, but the outer Ti matrix layer must be thinned to meet structural accuracy requirements. Thinning often leads to interfacial cracking and fibre breakage owing to machining stress, which presents a major challenge in manufacturing. The deformation mechanism during thinning is unclear and the lack of low-stress thinning methods significantly limits the potential applications of SiC<sub>f</sub>/Ti. This study investigates the macroscopic deformation and microstructural evolution of SiC<sub>f</sub>/Ti under ultrasonic cutting (UC) through orthogonal experiments. Compared with conventional cutting (CC), UC reduces cutting force by 20 % and surface residual stress by 60 %, while increasing subsurface residual stress and nano-hardness. The acoustic softening effect in UC reduces cutting force and surface stress, while high-frequency stress waves elevate subsurface stress. Digital image correlation (DIC) analysis reveals that the combined effects of loading and unloading cycles during UC produce an elastic recovery strain, reducing the overall deformation in SiC<sub>f</sub>/Ti during machining. Additionally, UC promotes grain refinement in the outer Ti layer of SiC<sub>f</sub>/Ti and induces a stress concentration at the α-Ti and β-Ti interface, facilitating the transformation of α-Ti to β-Ti. The presence of SiC fibres amplifies the effects of the ultrasonic energy, accelerating dislocation diffusion and annihilation, promoting dynamic recrystallisation, and reducing the dislocation density between the fibres. Moreover, UC homogenises and realigns the stress field at the SiC<sub>f</sub>/Ti interface, making the composition and structure of the interface more uniform and reducing interfacial damage. This study provides theoretical and practical insights into low-stress thinning, paving the way for broader applications of SiC<sub>f</sub>/Ti in advanced structural components.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"205 ","pages":"Article 104245"},"PeriodicalIF":14.0,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142929193","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}
Pub Date : 2025-02-01DOI: 10.1016/j.ijmachtools.2025.104246
Jiaxu Huang, Kang Xu, Shaolin Xu
Super-resolution laser machining represents a cutting-edge advancement in precision manufacturing, striving to approach or even exceed the optical diffraction limit to produce structures with exceptionally fine feature sizes, minimal heat-affected zones, and intricate freeform patterns. The present paper provides an overview of two principal approaches developed to achieve super-resolution: one is reducing the diffraction limit through the adoption of shorter laser wavelengths or advanced focusing techniques, and the other is surpassing the diffraction limit by advanced manipulation of the laser and its interactions with materials. With a deep investigation of the principles of these super-resolution laser machining methods, the review mainly explores the recent advancements in laser characteristics manipulation, materials innovation, and the integration of adaptive optics, high-speed laser scanning equipment, and feedback systems, all of which aim at enhancing machining resolution and broadening its applicability. Focusing on research frontiers and industrial applications, we also critically discussed future directions, potential problems, and possible solutions to smaller structure manufacturing regarding the light source, optical system, laser-matter interactions, and the surface evaluation methods. It also highlights the prospects for super-resolution laser machining, emphasizing its potential to transform precision manufacturing across industries.
{"title":"Super-resolution laser machining","authors":"Jiaxu Huang, Kang Xu, Shaolin Xu","doi":"10.1016/j.ijmachtools.2025.104246","DOIUrl":"10.1016/j.ijmachtools.2025.104246","url":null,"abstract":"<div><div>Super-resolution laser machining represents a cutting-edge advancement in precision manufacturing, striving to approach or even exceed the optical diffraction limit to produce structures with exceptionally fine feature sizes, minimal heat-affected zones, and intricate freeform patterns. The present paper provides an overview of two principal approaches developed to achieve super-resolution: one is reducing the diffraction limit through the adoption of shorter laser wavelengths or advanced focusing techniques, and the other is surpassing the diffraction limit by advanced manipulation of the laser and its interactions with materials. With a deep investigation of the principles of these super-resolution laser machining methods, the review mainly explores the recent advancements in laser characteristics manipulation, materials innovation, and the integration of adaptive optics, high-speed laser scanning equipment, and feedback systems, all of which aim at enhancing machining resolution and broadening its applicability. Focusing on research frontiers and industrial applications, we also critically discussed future directions, potential problems, and possible solutions to smaller structure manufacturing regarding the light source, optical system, laser-matter interactions, and the surface evaluation methods. It also highlights the prospects for super-resolution laser machining, emphasizing its potential to transform precision manufacturing across industries.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"205 ","pages":"Article 104246"},"PeriodicalIF":14.0,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143136846","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}
Pub Date : 2025-01-18DOI: 10.1016/j.ijmachtools.2025.104247
Huili Han, Hao Liu, Jiaxu Huang, Pei Qiu, Jun Li, Bi Zhang, Shaolin Xu
Diamond is an exceptional wide-bandgap semiconductor for electronics and quantum technologies. While femtosecond laser processing enables micro/nano fabrication of diamond, the dynamic atomic-level structural evolution during this process remains poorly understood, despite its critical impact on advanced applications. In this work, we investigate the multi-stage structural evolution of diamond under femtosecond laser irradiation, uncovering new scientific findings under laser-induced extreme conditions. The continuous input of pulse energy facilitates the rearrangement of local carbon atoms in the modified layer and partial phase transition layer, transitioning them from thermodynamically unstable to stable states. We introduce a sequential evolution pathway of nanocomposite carbon structures, and reinterpret the phenomenon previously broadly defined as “graphitization”. Specifically, the evolution of diaphite, diamond-OLC (onion-like carbon), and the transition from amorphous carbon to planar-oriented graphite are reported under femtosecond laser surface processing. These phase transitions are initiated by the rapid lattice heating, with their distribution influenced by near-field enhancement effects arisen from surface nanostructures. This work provides atomic-scale insights into diamond's response in femtosecond laser processing, offering a theoretical foundation for ultra-precision micro/nano fabrication of diamond and the development of functional carbon materials.
{"title":"Atomic-level insight into sequential evolution of nanocomposite carbon structures in femtosecond laser processing of diamond","authors":"Huili Han, Hao Liu, Jiaxu Huang, Pei Qiu, Jun Li, Bi Zhang, Shaolin Xu","doi":"10.1016/j.ijmachtools.2025.104247","DOIUrl":"10.1016/j.ijmachtools.2025.104247","url":null,"abstract":"<div><div>Diamond is an exceptional wide-bandgap semiconductor for electronics and quantum technologies. While femtosecond laser processing enables micro/nano fabrication of diamond, the dynamic atomic-level structural evolution during this process remains poorly understood, despite its critical impact on advanced applications. In this work, we investigate the multi-stage structural evolution of diamond under femtosecond laser irradiation, uncovering new scientific findings under laser-induced extreme conditions. The continuous input of pulse energy facilitates the rearrangement of local carbon atoms in the modified layer and partial phase transition layer, transitioning them from thermodynamically unstable to stable states. We introduce a sequential evolution pathway of nanocomposite carbon structures, and reinterpret the phenomenon previously broadly defined as “graphitization”. Specifically, the evolution of diaphite, diamond-OLC (onion-like carbon), and the transition from amorphous carbon to planar-oriented graphite are reported under femtosecond laser surface processing. These phase transitions are initiated by the rapid lattice heating, with their distribution influenced by near-field enhancement effects arisen from surface nanostructures. This work provides atomic-scale insights into diamond's response in femtosecond laser processing, offering a theoretical foundation for ultra-precision micro/nano fabrication of diamond and the development of functional carbon materials.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"206 ","pages":"Article 104247"},"PeriodicalIF":14.0,"publicationDate":"2025-01-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143157268","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}
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