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Review of physicochemical-assisted nanomanufacturing processes for wide-bandgap semiconductor wafers 宽禁带半导体晶圆的物理化学辅助纳米制造技术综述
IF 18.8 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2025-08-12 DOI: 10.1016/j.ijmachtools.2025.104321
Kazuya Yamamura , Hui Deng , Yasuhisa Sano , Junji Murata , Xu Yang , Rongyan Sun
Nanomanufacturing involves not only fabricating nanoscale three-dimensional microstructures but also achieving nanoscale surface planarization and smoothing—an indispensable requirement in semiconductor-wafer processing. Wide-bandgap semiconductors such as SiC, GaN, diamond, and AlN combine high hardness, brittleness, and chemical inertness, making it exceptionally difficult to produce large size wafers with damage-free, atomic-level smoothness that meets the performance demands of next-generation devices. Physical–chemical composite methods, which marry the high-efficiency planarization of mechanical removal with the damage-free of chemical reactions, have emerged as the most promising route to overcome this challenge. Chemical mechanical polishing (CMP), the first-generation composite technique, was well established in industry; however, its low material removal rates, extensive consumable use, and environmental burden were increasingly problematic as wafer sizes grow and new wide-bandgap materials become mainstream. This review surveys the principal physicochemical processing techniques and examines four representative approaches—plasma-assisted polishing (PAP), plasma-based atomic-selective etching (PASE), catalyst-assisted etching (CARE), and electrochemical mechanical polishing (ECMP). A systematic comparison of their mechanisms, advantages, and limitations clarifies how these methods maintain crystal integrity while enabling selective material removal, thereby delivering atomically smooth surfaces with significantly higher throughput. The review provides both theoretical insight and practical guidance for cost-effective, atomically precise processing of wide-bandgap semiconductor wafers.
纳米制造不仅涉及制造纳米级三维微结构,还涉及实现纳米级表面平面化和光滑化,这是半导体晶圆加工中不可或缺的要求。宽带隙半导体,如SiC、GaN、金刚石和AlN,结合了高硬度、脆性和化学惰性,使得生产具有无损伤、原子级光滑度的大尺寸晶圆,满足下一代器件的性能要求,变得异常困难。物理化学复合方法结合了机械去除的高效率平面化和化学反应的无损伤性,已经成为克服这一挑战的最有希望的途径。化学机械抛光(CMP)是第一代复合材料技术,在工业上已经得到了很好的应用;然而,随着晶圆尺寸的增长和新型宽带隙材料的主流化,其材料去除率低、耗材广泛以及环境负担日益成为问题。本文综述了主要的物理化学加工技术,并研究了四种具有代表性的方法——等离子体辅助抛光(PAP)、等离子体基原子选择性蚀刻(PASE)、催化剂辅助蚀刻(CARE)和电化学机械抛光(ECMP)。系统地比较了它们的机制、优点和局限性,阐明了这些方法如何在实现选择性材料去除的同时保持晶体完整性,从而提供具有显着更高吞吐量的原子光滑表面。该综述为低成本、原子精度高的宽禁带半导体晶圆加工提供了理论见解和实践指导。
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引用次数: 0
A novel strategy for electrochemical additive manufacturing: Femtosecond laser-assisted localized electrochemical deposition 电化学增材制造的新策略:飞秒激光辅助局部电化学沉积
IF 18.8 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2025-08-08 DOI: 10.1016/j.ijmachtools.2025.104319
Zhaoqiang Zou , Wanfei Ren , Jinkai Xu , Hanhan Wei , Zhanjiang Yu , Ningqian Tang , Huadong Yu
Localized electrochemical deposition (LECD) exhibits significant advantages in fabricating microscale 3D metallic structures. However, conventional LECD technologies are inherently constrained by diffusion-controlled mechanisms, where pursuit of enhanced deposition efficiency inevitably degrades deposition quality (such as increased surface roughness and internal defects), consequently impairing structural mechanical properties. This study presents a femtosecond laser-assisted localized electrochemical deposition (FsLA-LECD) technology. By precisely coupling femtosecond laser irradiation with the electrodeposition microzone and leveraging laser energy to regulate electrodeposition process, this approach simultaneously achieves efficient fabrication of complex metallic microstructures with enhanced mechanical performance. The regulating effects of laser irradiation on mass transfer, nucleation kinetics, and grain growth evolution are investigated throughout the evolution process of point-surface-structure. Experimental and computational analysis elucidate that the laser-induced Marangoni effect within the reaction microenvironment enhances microzone electrolyte replenishment, consequently elevating deposition current density. This results in a volume deposition rate of 15.47 μm3/s, representing a 3 times enhancement over laser-free conditions. Laser-mediated regulation of deposition rates enabled fabrication of uniform-diameter, bamboo-like, and hourglass-shaped microstructures. Furthermore, pulsed laser energy facilitated stepwise current amplification, thereby inducing nanotwin formation within copper micro-geometrical features. This approach attained a tensile yield strength of 1.08 GPa, significantly surpassing that of traditional electrodeposited counterparts. This work demonstrates the capability of FsLA-LECD to simultaneously enable high-efficiency manufacturing and enhanced mechanical properties, establishing the groundwork for innovative approaches to high-performance micromanufacturing.
局部电化学沉积(LECD)在制造微尺度三维金属结构方面具有显著的优势。然而,传统的LECD技术本身就受到扩散控制机制的限制,在这种机制下,追求提高沉积效率不可避免地会降低沉积质量(如增加表面粗糙度和内部缺陷),从而损害结构力学性能。本研究提出了一种飞秒激光辅助定位电化学沉积(FsLA-LECD)技术。该方法通过将飞秒激光照射与电沉积微区精确耦合,利用激光能量调节电沉积过程,同时实现了复杂金属微结构的高效制造,并提高了机械性能。研究了激光辐照对点面结构演化过程中传质、成核动力学和晶粒生长演化的调控作用。实验和计算分析表明,反应微环境中激光诱导的马兰戈尼效应增强了微区电解质的补充,从而提高了沉积电流密度。这导致了15.47 μm3/s的体积沉积速率,比无激光条件下提高了3倍。激光介导的沉积速率调节使直径均匀,竹状和沙漏状微结构的制造成为可能。此外,脉冲激光能量促进了电流的逐步放大,从而在铜的微观几何特征中诱导纳米孪晶的形成。该方法获得了1.08 GPa的抗拉屈服强度,大大超过了传统电沉积的同类材料。这项工作证明了FsLA-LECD同时实现高效率制造和增强机械性能的能力,为高性能微制造的创新方法奠定了基础。
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引用次数: 0
Understanding the surface polishability and hardness-softening mechanisms of martensitic mould steel in multi-mode nanosecond laser polishing 了解马氏体模具钢在多模纳秒激光抛光中的表面可抛光性和硬度软化机理
IF 18.8 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2025-07-25 DOI: 10.1016/j.ijmachtools.2025.104311
Erju Liu , Donghe Zhang , La Han , Zhikun Liu , Debin Shan , Bin Guo , Jie Xu
Laser polishing is an efficient, reliable, and environmentally friendly surface-finishing technique aimed at improving the surface quality. However, its application to martensitic mould steel is limited by surface-softening issues induced by the pronounced thermal effects of conventional continuous-wave laser polishing. This study proposes a multi-mode nanosecond laser polishing approach that employs a millimetre-diameter beam with top-hat energy distribution to mitigate the thermal effects and alleviate surface softening. A key challenge is achieving high-quality polishing at shallow melting depths. Further, the proposed process may alter the surface-softening mechanism when considering the unique phase-transformation behaviour of martensitic mould steel. To clarify these aspects, the characteristics of multi-mode nanosecond laser polishing, related to the process and properties, are investigated via finite-element simulations and experiments. The results demonstrate that, unlike the multi-directional melt flow induced by the intense melt pool reaction in continuous-wave laser polishing, multi-mode nanosecond laser polishing drives long-range horizontal melt flow and simultaneously induces multiple convex peaks to fill concave valleys, thereby achieving high-quality surface smoothing (Sa = 0.23 μm) with a minimal melting depth (<2 μm). Moreover, a novel surface-softening mechanism involving the synergistic induction of residual austenite enrichment (up to 90 %) in the fusion zone and martensite tempering effects in the heat-affected zone is presented, which contrasts with the traditional mechanism that relies solely on tempering-induced softening in the heat-affected zone. This study presents a low-thermal-effect, high-quality, and high-efficiency polishing solution for metal components, while advancing the theoretical understanding of hardness-softening mechanisms in the laser manufacturing of martensitic steel.
激光抛光是一种高效、可靠、环保的表面处理技术,旨在提高表面质量。然而,由于传统连续波激光抛光的明显热效应导致表面软化,限制了其在马氏体模型钢上的应用。本研究提出了一种多模纳秒激光抛光方法,该方法采用直径为毫米的能量顶帽分布光束来减轻热效应和表面软化。一个关键的挑战是在较浅的熔化深度实现高质量的抛光。此外,考虑到马氏体模具钢独特的相变行为,所提出的工艺可能会改变表面软化机制。为了阐明这些方面,通过有限元模拟和实验研究了多模纳秒激光抛光的工艺和性能特征。结果表明,与连续波激光抛光中强烈熔池反应引起的多向熔体流动不同,多模纳秒激光抛光驱动长距离水平熔体流动,同时诱导多个凸峰填充凹谷,从而以最小的熔化深度(<2 μm)实现高质量的表面光滑(Sa = 0.23 μm)。此外,提出了一种新的表面软化机制,该机制涉及熔合区残余奥氏体富集(高达90%)和热影响区马氏体回火效应的协同诱导,这与传统的仅依赖回火诱导热影响区的软化机制形成了对比。本研究提出了一种低热效应、高质量、高效率的金属零件抛光解决方案,同时推进了对马氏体钢激光加工硬度-软化机理的理论认识。
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引用次数: 0
Model-driven 3D laser focus shifting for precision fabrication of microstructures in transparent flexible polymers 模型驱动的三维激光聚焦转移在透明柔性聚合物微结构精密制造中的应用
IF 14 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2025-07-12 DOI: 10.1016/j.ijmachtools.2025.104310
Rui Chen , Chunjin Wang , Tao Luo , Wenjun Xu , Qixian Zhang , Jie Zhou , Rui Gao , Chi Fai Cheung , Wei Zhou
Micro-engineered transparent flexible polymers components play a crucial role in various microsystem fields, such as flexible electronics and microfluidics. However, conventional laser fabrication techniques face significant challenges in overcoming issues of energy deposition inaccuracies and focal mismatch, which hinder the fabrication of high-fidelity and controllable 3D microstructure in transparent polymer materials. In this study, we propose a universal 3D dynamic-focusing laser (3D-DFL) fabrication strategy using an infrared (IR) picosecond laser. By dynamically adjusting the Z-axis focus in real time, the system effectively compensates for the depth shifts caused by ablation, ensuring consistent energy deposition and stable fabrication quality. High-speed imaging reveals a three-stage ablation mechanism (stabilization, expansion, and contraction) under laser irradiation. To support the multi-layer dynamic shifting process of the 3D-DFL approach, a universal ablation depth prediction model was established to compensate depth deviations during laser-material interactions. The validity of the model has been proven by its ability to predict ablation depth in different polymer materials with low mean absolute percentage errors (MAPE), achieving 5.99 % for polydimethylsiloxane (PDMS) and 2.68 % for polyethylene terephthalate (PET). The model enables the accurate fabrication of 3D microstructures, achieving normalized peak-to-valley deviations within 8.0 % and normalized root-mean-square deviations below 3.0 %, with an arithmetic surface roughness of approximately 2 μm. The 3D dynamic-focusing laser (3D-DFL) approach enables rapid tailoring of complex geometries, including protruding and recessed microstructures on PDMS and PET substrates. Experimental validation highlights its capability to fabricate functional components such as flexible pressure sensors, microfluidic chips, and ultrasonic droplet manipulation platforms. This study provides an efficient and reliable pathway for the scalable fabricating of high-precision transparent polymers micro-engineered devices and promotes the advancement of research and industry in advanced flexible microsystems.
微工程透明柔性聚合物组件在柔性电子和微流体等微系统领域发挥着至关重要的作用。然而,传统的激光制造技术在克服能量沉积不精确和焦点失配问题方面面临着重大挑战,这阻碍了在透明聚合物材料中制造高保真和可控的三维微观结构。在这项研究中,我们提出了一种使用红外皮秒激光器的通用三维动态聚焦激光器(3D- dfl)制造策略。该系统通过实时动态调整z轴聚焦,有效补偿了烧蚀引起的深度偏移,保证了能量沉积的一致性和稳定的制造质量。高速成像揭示了激光照射下的三阶段消融机制(稳定、膨胀和收缩)。为了支持3D-DFL方法的多层动态位移过程,建立了一个通用烧蚀深度预测模型,以补偿激光-材料相互作用过程中的深度偏差。该模型能够预测不同聚合物材料的烧蚀深度,平均绝对百分比误差(MAPE)较低,聚二甲基硅氧烷(PDMS)的平均绝对百分比误差为5.99%,聚对苯二甲酸乙二醇酯(PET)的平均绝对百分比误差为2.68%。该模型能够精确地制造3D微结构,实现归一化峰谷偏差在8.0%以内,归一化均方根偏差在3.0%以下,算术表面粗糙度约为2 μm。3D动态聚焦激光(3D- dfl)方法可以快速定制复杂的几何形状,包括PDMS和PET基板上的突出和凹陷微结构。实验验证强调了其制造功能组件的能力,如柔性压力传感器,微流控芯片和超声波液滴操作平台。本研究为高精度透明聚合物微工程器件的规模化制造提供了一条高效可靠的途径,促进了先进柔性微系统的研究和工业发展。
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引用次数: 0
Systematic review of Cutting Force Measuring Systems in machining: Principles, design, filtering techniques and applications 机械加工中切削力测量系统综述:原理、设计、滤波技术和应用
IF 14 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2025-07-12 DOI: 10.1016/j.ijmachtools.2025.104308
Pengfei Zhang , Dongbo Hong , Giovanni Totis , Federico Scalzo , Zengbin Yin , Liming Shu , Naohiko Sugita
Cutting force measurement plays a key role in modern manufacturing, supporting machinability testing, tool development, process optimization, real-time monitoring and control, and indirect evaluation of part quality. Over the past 50 years, numerous Cutting Force Measuring Systems (CFMS) have been developed and applied successfully in both laboratory and industrial settings. However, their adoption in real industrial environments has been limited by several practical drawbacks. Today, the need for more effective, less invasive, and lower-cost sensing solutions is driving renewed interest in CFMS and fostering deeper integration into manufacturing systems. Despite their relevance, comprehensive and updated reviews of CFMS are scarce. This systematic review aims to present the fundamental principles of cutting force sensing, outline the main types of CFMS, and provide general design guidelines. The strengths and limitations of each type of CFMS are discussed and compared—particularly their limited frequency bandwidth, which can be further reduced when integrated into actual machining systems. To address these challenges, advanced identification and filtering techniques are described, focusing on the dynamic relationship between input forces and measured outputs, along with modern methods for their determination. Parametric (Kalman) filters are introduced, while greater emphasis is placed on recent non-parametric filters, which offer easier implementation in industrial contexts. The review also highlights key CFMS applications, including machinability testing, cutting force model identification, tool development and tool condition monitoring. Emerging trends are examined, such as PVDF-based sensors, the Universal Inverse Filter, and other innovative technologies. Current research challenges involve developing solutions for wireless power transmission, fast calibration, low-latency data transfer, and embedded signal processing. Continued progress in CFMS research and application will be essential to advancing intelligent manufacturing and improving industrial competitiveness.
切削力测量在现代制造业中起着关键作用,它支持可加工性测试、刀具开发、工艺优化、实时监测和控制以及零件质量的间接评价。在过去的50年里,许多切削力测量系统(CFMS)已经被开发出来并成功地应用于实验室和工业环境中。然而,它们在实际工业环境中的应用受到一些实际缺陷的限制。如今,对更有效、侵入性更低、成本更低的传感解决方案的需求正在推动人们对CFMS的重新关注,并促进与制造系统的更深层次集成。尽管它们具有相关性,但对CFMS的全面和更新的评论很少。本系统综述旨在介绍切削力传感的基本原理,概述CFMS的主要类型,并提供一般设计指南。讨论和比较了每种类型CFMS的优点和局限性,特别是它们的有限频率带宽,当集成到实际加工系统中时,可以进一步降低其带宽。为了解决这些挑战,介绍了先进的识别和过滤技术,重点是输入力和测量输出之间的动态关系,以及它们的实验识别的现代方法。介绍了参数(卡尔曼)滤波器,同时更强调最近的非参数滤波器,它们在工业环境中更容易实现。该综述还强调了CFMS的关键应用,包括可加工性测试、切削力模型识别、刀具开发和刀具状态监测。研究了新兴趋势,如基于pvdf的传感器,通用反滤波器和其他创新技术。目前的研究挑战包括开发无线电力传输、快速校准、低延迟数据传输和嵌入式信号处理的解决方案。不断推进CFMS研究和应用,对推进智能制造和提高产业竞争力至关重要。
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引用次数: 0
Decoupling the heat source and remelting depth for equiaxed transition in wire arc additive manufacturing of titanium alloy 钛合金丝弧增材制造等轴转变热源与重熔深度解耦
IF 14 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2025-07-05 DOI: 10.1016/j.ijmachtools.2025.104309
Yimin Zhuo , Fu Chen , Yongqiang Ye , Jiaming Zhang , Zichao Wei , Ke Chen , Jianwen Le , Guangfa Huang , Yuanfei Han , Bo Cui , Weijie Lu
The columnar to equiaxed transition (CET) of grain structures presents significant challenges in titanium alloy additive manufacturing (AM), especially in wire arc additive manufacturing (WAAM) with highly localized heat input and large temperature gradient. In this work, the strategy of decoupling the relationship between heat source and remelting depth was proposed, which was achieved by altering the electrode connection type with arc discharge between the tungsten electrode and the welding wire (IPAW-Wire method). Compared to the conventional WAAM methods based on tungsten inert gas welding (Conventional-TIG method), the IPAW-Wire method reduces the average β grains width from 2 mm to around 200 μm and the maximum texture intensity by approximately three times. The decoupling strategy combined with thermal undercooling and periodic solidification effect of low-frequency pulse arc promotes CET results. The IPAW-Wire method increases tensile strength by 50–80 MPa without altering the alloy composition or making external equipment modifications, and significantly weaken the anisotropy of mechanical properties, both in terms of ultimate strength and plasticity. The strength enhancement and anisotropy reduction are attributed to the coupling of β grains refinement, weakened α crystallographic texture, fine needle-like α′ martensite, and high-density dislocation with multiple types of <a> dislocations, <c> dislocations and <c+a> dislocations. This innovative IPAW-Wire method effectively mitigates coarse columnar grains and anisotropy by decoupling the relationship between heat source and remelting depth. This control strategy can inspire other heat sources and material additive manufacturing process, addressing hotspot challenges such as programmable microstructure, metamaterials structure, multi-material, and bioinspired printing.
晶粒结构的柱状向等轴转变(CET)是钛合金增材制造(AM),特别是在热输入高度局域化和温度梯度大的电弧增材制造(WAAM)中面临的重大挑战。本文提出了一种解耦热源与重熔深度关系的策略,该策略通过改变钨电极与焊丝之间电弧放电的电极连接方式(IPAW-Wire法)实现。与传统的钨惰性气体焊接方法(conventional - tig法)相比,IPAW-Wire方法将β晶粒的平均宽度从2 mm减小到200 μm左右,最大织构强度减小了约3倍。结合热过冷和低频脉冲电弧周期性凝固效应的解耦策略促进了瞬变效应的产生。IPAW-Wire方法在不改变合金成分或不进行外部设备改造的情况下,可将拉伸强度提高50-80 MPa,并且在极限强度和塑性方面显著减弱力学性能的各向异性。强度增强和各向异性降低是由于β晶粒细化、α晶体织构减弱、细针状α′马氏体和高密度位错与多种类型的<;混乱,& lt; c>位错和<;c+a>;混乱。这种创新的IPAW-Wire方法通过解耦热源和重熔深度之间的关系,有效地减轻了粗柱状晶粒和各向异性。这种控制策略可以启发其他热源和材料增材制造工艺,解决可编程微结构、超材料结构、多材料和仿生打印等热点挑战。
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引用次数: 0
Quantitative study of oxidation mechanism in photoelectrochemical mechanical polishing of difficult-to-process semiconductor wafers 难加工半导体晶圆光电机械抛光氧化机理的定量研究
IF 14 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2025-06-27 DOI: 10.1016/j.ijmachtools.2025.104307
Yuewen Sun , Shang Gao , Bi Zhang , Yang Zhao , Xiaoguang Guo , Renke Kang , Zhigang Dong
The excellent properties of gallium nitride (GaN), silicon carbide (SiC), and diamond make them the most promising semiconductor materials for the future. However, their extremely stable chemical properties and high hardness lead to a low efficiency in chemical mechanical polishing (CMP). Photoelectrochemical mechanical polishing (PECMP) is an efficient and high-quality machining method for difficult-to-process semiconductor materials, integrating photo, electric, chemical, and mechanical fields. However, the coupling of these fields creates complex mechanisms, making it difficult to quantitatively describe the oxidation mechanism driven by the electric field. As a result, selecting the appropriate applied voltage for specific polishing requirements is challenging. To address this, a detailed analysis of the transfer of electrons and holes at the wafer/solution interface was conducted, and an innovative relationship between variations in the energy field and the wafer surface potential in PECMP was established. For the first time, the Poisson equation was applied to the wafer/solution interface, and a novel theoretical model for the oxidation rate and applied voltage on the wafer surface in PECMP was developed. Specifically, at the voltage threshold, the surface charge type changes from electrons to holes, resulting in a significant increase in hole density. Finally, the model was validated through surface modification and PECMP tests. This research not only presents an innovative theoretical method for determining the applied voltage in photoelectric field-assisted polishing for any semiconductor material but also offers new insights into how surface charge transitions between electrons and holes under varying applied voltages can significantly influence polishing efficiency in photoelectric field-assisted polishing.
氮化镓(GaN)、碳化硅(SiC)和金刚石的优异性能使它们成为未来最有前途的半导体材料。然而,由于其化学性质非常稳定,硬度高,导致化学机械抛光效率低。光电化学机械抛光(PECMP)是一种集光、电、化学、机械等多个领域于一体的高效、高质量的难加工半导体材料加工方法。然而,这些场的耦合产生了复杂的机制,使得难以定量描述电场驱动的氧化机制。因此,为特定的抛光要求选择合适的施加电压是具有挑战性的。为了解决这个问题,我们对晶圆/溶液界面上的电子和空穴转移进行了详细的分析,并在PECMP中建立了能量场变化与晶圆表面电位之间的创新关系。首次将泊松方程应用于晶圆/溶液界面,建立了PECMP中晶圆表面氧化速率和外加电压的理论模型。具体来说,在电压阈值处,表面电荷类型由电子变为空穴,导致空穴密度显著增加。最后,通过表面改性和PECMP试验对模型进行了验证。该研究不仅为确定任何半导体材料的光电场辅助抛光中的施加电压提供了一种创新的理论方法,而且为在不同的施加电压下电子和空穴之间的表面电荷跃迁如何显著影响光电场辅助抛光中的抛光效率提供了新的见解。
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引用次数: 0
Novel multi-axis differential velocity sideways extrusion process for 3D curved profiles: Feasibility and forming mechanisms studies 三维弯曲型材的新型多轴差速侧向挤压工艺:可行性及成形机理研究
IF 14 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2025-06-12 DOI: 10.1016/j.ijmachtools.2025.104306
Yutong Sun , Junquan Yu , Guoqun Zhao , Xiqing Ge
3D curved profiles or extrudates are widely used in industry; however, their flexible manufacturing with very few processing steps remains a great challenge. In this study, a novel extrusion-bending integrated process, termed multi-axis differential velocity sideways extrusion (MX-DVSE), was developed to form controlled 3D curved extrudates within a single operation, and its forming mechanics was clarified by experiments and finite element modelling. The MX-DVSE equipment was set up, and a set of dies was designed to perform a series of experiments in which two pairs of opposing punches were moved at different velocities. During the MX-DVSE process, the superposition of the velocity gradients generated by the four extrusion velocities induces the bending deformation of the extrudates with a controllable bending radius and deflection angle. The bending radius is determined by velocity gradient, velocity gradient ratio, and extrusion ratio. The bending radius decreased with an increase in the deviation of the velocity gradients from 1, reduction in the velocity gradient ratio, and increase in the extrusion ratio. The velocity gradient and velocity gradient ratio can be unified into a proposed indicator, termed the bending radius control factor, which exhibits a monotonic relationship with the bending radius. The deflection angle depends on the extrusion velocity and the velocity gradient. The bending plane of the extrudate was close to the direction of the velocity gradient, which deviated from 1 or the direction of the maximum velocity. This is reflected in another proposed indicator: the deflection angle control factor. The feasibility of the MX-DVSE technique was further verified by considering the specific shape and size of 3D curved extrudates as the forming targets. The experimental results show that MX-DVSE can form 3D curved extrudates with acceptable dimensional accuracy, and the proposed control factors for the bending radius and deflection angle can accurately control the shape of the 3D curved extrudates. Moreover, compared to forward extrusion, MX-DVSE was more effective in refining grains and enhancing the strength and ductility of extrudates with the same extrusion parameters. This study demonstrates that MX-DVSE has great potential for the development and application of flexible manufacturing of 3D curved extrudates.
三维曲面型材或挤出物在工业中应用广泛;然而,它们的柔性制造和很少的加工步骤仍然是一个巨大的挑战。在这项研究中,开发了一种新的挤压弯曲集成工艺,称为多轴差速侧向挤压(MX-DVSE),可以在一次操作中形成受控的3D弯曲挤出物,并通过实验和有限元建模阐明了其成形机理。建立了MX-DVSE设备,设计了一套模具,进行了一系列实验,其中两对相反的冲头以不同的速度移动。在MX-DVSE过程中,四种挤出速度产生的速度梯度叠加,使挤出物发生弯曲变形,弯曲半径和偏转角可控。弯曲半径由速度梯度、速度梯度比和挤压比决定。弯曲半径随速度梯度与1的偏差增大、速度梯度比减小、挤压比增大而减小。速度梯度和速度梯度比可以统一为一个指标,称为弯曲半径控制因子,它与弯曲半径呈单调关系。偏转角度取决于挤压速度和速度梯度。挤出物弯曲面接近速度梯度方向,偏离最大速度方向1。这反映在另一个拟议的指标:偏转角控制系数。以三维弯曲挤出物的特定形状和尺寸为成形目标,进一步验证了MX-DVSE技术的可行性。实验结果表明,MX-DVSE能够以可接受的尺寸精度形成三维弯曲挤出物,所提出的弯曲半径和挠度控制因子能够精确控制三维弯曲挤出物的形状。此外,与正挤压相比,在相同挤压参数下,MX-DVSE能更有效地细化晶粒,提高挤压物的强度和塑性。该研究表明,MX-DVSE在三维弯曲挤出物的柔性制造中具有很大的开发和应用潜力。
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引用次数: 0
A review of robust thermal error reduction of machine tools 机床热误差鲁棒减小研究进展
IF 14 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2025-06-01 DOI: 10.1016/j.ijmachtools.2025.104298
Lingtao Weng , Toru Kizaki , Chi Ma , Weiguo Gao , Daisuke Kono
Thermal error reduction in machine tools has attracted increasing attention owing to its influence on the accuracy, productivity, and energy efficiency of machining processes. In several traditional studies, the thermal error has been modeled as a straightforward relationship between the heat input and the output machining error. However, the demand for thermal error reduction in complex practical conditions with the interactive variation of influencing factors has been increasing because energy saving and a predictive countermeasure for defects, even in transient conditions, are expected. Robust reduction in the thermal error under such complex conditions remains a challenging issue. This paper reviews the strategy and methodology for realizing robust thermal error reduction considering the variation in influencing factors. A comprehensive model of thermal error that considers the interaction of thermal and mechanical systems is described to provide an overview of the targeted topic. Specific methodologies published over the last 15 years, such as adaptive modeling and compensation, machine design optimization, and temperature control, are reviewed. We focus on the evolution of data-driven models and digital twin systems for thermal error compensation by describing their implementation frameworks. An open question regarding strategy selection for thermal error compensation considering uncertainty is discussed. This review reveals the current research gap and provides an outlook for future challenges in realizing real-time and adaptive thermal error compensation.
机床热误差的减小由于其对加工过程的精度、生产率和能源效率的影响而受到越来越多的关注。在一些传统的研究中,热误差被建模为热输入和输出加工误差之间的直接关系。然而,在影响因素相互作用变化的复杂实际条件下,由于期望节能和对缺陷的预测对策,即使在瞬态条件下,对热误差减小的需求也在增加。在如此复杂的条件下,如何有效地减小热误差仍然是一个具有挑战性的问题。本文综述了考虑影响因素变化而实现鲁棒热误差减小的策略和方法。考虑到热和机械系统的相互作用的热误差的综合模型被描述为提供目标主题的概述。回顾了过去15年来发表的具体方法,如自适应建模和补偿,机器设计优化和温度控制。我们通过描述其实现框架,重点关注热误差补偿的数据驱动模型和数字孪生系统的发展。讨论了考虑不确定性的热误差补偿策略选择问题。本文综述了目前的研究差距,并对实现实时和自适应热误差补偿的未来挑战进行了展望。
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引用次数: 0
A high efficiency pre-dissolution electrochemical polishing method for improving surface uniformity in additively manufactured alloys 一种提高增材制造合金表面均匀性的高效预溶电化学抛光方法
IF 14 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2025-05-24 DOI: 10.1016/j.ijmachtools.2025.104297
Jierui Mu , Qiang Lu , Zijue Tang , Yi Wu , Haowei Wang , Hongze Wang
Electrochemical polishing (ECP) offers significant advantages in reducing surface roughness of complex additively manufactured (AMed) components. However, conventional one-step ECP methods hinder further removal of near-surface defects, such as inherent adhesive powders and step effects, owing to the simultaneous dissolution and smoothing processes. Additionally, the topological conformity between the formed high-resistance oxide layer and the metal matrix limits the polishing effectiveness, producing undesirable surface inconsistency and poor dimensional accuracy. In this study, we introduce a pre-dissolution step prior to the conventional ECP process, namely pre-dissolution ECP. This approach is based on the electrochemical dissolution behavior of adhesive powders and the melt pool (MP) structure to transform the irregular, rough as-built surface into a pre-dissolved MP morphology with a uniform current density distribution, aiming to optimize the subsequent ECP process. By combining in situ X-ray synchrotron radiation observation with comparative quantitative analysis of samples before and after mechanical polishing, precise dissolution parameters were determined to achieve a polished surface with uniformly distributed height differences. For AMed Al alloys with high Si content, when the percentage change rate of dissolved areas of the cross-sectional profile in the pre-dissolution step is 0.060 ± 0.003 %/min, different adhesive powder regions exhibit consistent height differences on the pre-dissolved surface. During the subsequent polishing step, compared to direct ECP (∼5.3 μm), the isotropic etching-based smoothing effect in NaOH solution further reduces surface roughness of the pre-dissolved surface to ∼1.5 μm, and the corresponding standard deviation of height difference is reduced by 80.7 %. Moreover, the use of low voltage and the one-time removal of surface cluster layers ensures improved roundness tolerance (85.7 %) and capillary action (304.4 %) for AMed heat pipes with internal channels (Φ1.4 mm) after polishing. This pre-dissolution strategy mitigates the complexity and randomness of as-built surface features, facilitating better ECP performance. It can also be integrated with advanced ECP technologies, thereby expanding the application potential of AMed structures, including but not limited to internal channels.
电化学抛光(ECP)在降低复杂增材制造(AMed)部件的表面粗糙度方面具有显著的优势。然而,传统的一步ECP方法阻碍了进一步去除近表面缺陷,如固有的粘合剂粉末和台阶效应,由于同时溶解和平滑过程。此外,形成的高阻氧化层与金属基体之间的拓扑一致性限制了抛光效果,产生不良的表面不一致和尺寸精度差。在本研究中,我们在常规ECP工艺之前引入了一个预溶步骤,即预溶ECP。该方法基于粘接粉末的电化学溶解行为和熔池(MP)结构,将不规则、粗糙的建成表面转化为电流密度分布均匀的预溶解MP形态,旨在优化后续的ECP工艺。通过现场x射线同步辐射观测与机械抛光前后样品的对比定量分析相结合,确定了精确的溶解参数,获得了高度差分布均匀的抛光表面。对于高Si含量的AMed铝合金,当预溶步骤中截面轮廓溶解区域百分比变化率为0.060±0.003% /min时,不同的粘接粉末区域在预溶表面呈现一致的高度差异。在随后的抛光步骤中,与直接ECP (~ 5.3 μm)相比,NaOH溶液中基于各向同性蚀刻的平滑效应进一步将预溶表面的表面粗糙度降低到~ 1.5 μm,相应的高度差标准差降低了80.7%。此外,使用低电压和一次性去除表面簇层可确保抛光后具有内部通道(Φ1.4 mm)的AMed热管的圆度公差(85.7%)和毛细作用(304.4%)得到改善。这种预溶解策略减轻了建成表面特征的复杂性和随机性,促进了更好的ECP性能。它还可以与先进的ECP技术集成,从而扩大AMed结构的应用潜力,包括但不限于内部通道。
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引用次数: 0
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International Journal of Machine Tools & Manufacture
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