Pub Date : 2023-05-04DOI: 10.1080/10910344.2023.2224870
Jianzhi Chen, Yan Wang, Guochao Li, Z. Xu, Han Gao, Xucheng Deng, Shuhao Zhang, Honggen Zhou
Abstract The generation of grinding cracks during the grinding process will adversely affect the service performance of the workpiece and even cause the workpiece to be scrapped. However, the microscopic formation mechanism of grinding cracks is still unclear at present. In this regard, the morphologies of grinding cracks on the surface of the cam were characterized, and the initiation and propagation behaviors of grinding cracks were analyzed from the perspectives of element composition, micro-structure and surface work hardening. Based on the experimental results and analysis, the generation mechanism of grinding cracks is clarified, and measures to prevent the grinding cracks are proposed.
{"title":"Investigation on grinding-induced cracking mechanism of 40Cr steel camshaft","authors":"Jianzhi Chen, Yan Wang, Guochao Li, Z. Xu, Han Gao, Xucheng Deng, Shuhao Zhang, Honggen Zhou","doi":"10.1080/10910344.2023.2224870","DOIUrl":"https://doi.org/10.1080/10910344.2023.2224870","url":null,"abstract":"Abstract The generation of grinding cracks during the grinding process will adversely affect the service performance of the workpiece and even cause the workpiece to be scrapped. However, the microscopic formation mechanism of grinding cracks is still unclear at present. In this regard, the morphologies of grinding cracks on the surface of the cam were characterized, and the initiation and propagation behaviors of grinding cracks were analyzed from the perspectives of element composition, micro-structure and surface work hardening. Based on the experimental results and analysis, the generation mechanism of grinding cracks is clarified, and measures to prevent the grinding cracks are proposed.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"27 1","pages":"308 - 324"},"PeriodicalIF":2.7,"publicationDate":"2023-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49385432","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"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 : 2023-03-27DOI: 10.1080/10910344.2023.2194961
Israa Dheyaa Khalaf Alrubaye, G. Fantoni
Abstract The electrical discharge machining process is useful to manufacture complex shaped parts with high accuracy; however, it has unfriendly environmental impacts such as toxic emissions and health hazards; these impacts do not align with the recent orientation toward green industrial environments. Nowadays, researchers, practitioners, and designers focus on implementing sustainable EDM-based green environmental principles. Thus, this article presents an extensive overview of most of the enhancement and eco-friendly technologies for improving the efficiency of the EDM process (material removal rate, lower electrode wear ratio, and surface roughness) and lowering the environmental impacts. These enhancement technologies have been classified into four drivers. The advantages and limitations of each technology have been discussed. Then, the maturity of each technology has been estimated through technology readiness levels. Highlights EDM technology is in its maturity stage. The main research contributions in the last 10 years are on. The highest mature technologies are the cryogenic treatment, hybrid EDUVM, and PMEDM technologies. The CNT powder mixed EDM and the additive manufacturing technologies have been successfully applied in roughing processes and we expect more industrial applications. The high energy consumption with hybrid EDAM technology is nowadays limiting its maturity therefore further research is necessary to come to an industrially viable process.
{"title":"Toward green electrical discharge machining (EDM): state of art and outlook","authors":"Israa Dheyaa Khalaf Alrubaye, G. Fantoni","doi":"10.1080/10910344.2023.2194961","DOIUrl":"https://doi.org/10.1080/10910344.2023.2194961","url":null,"abstract":"Abstract The electrical discharge machining process is useful to manufacture complex shaped parts with high accuracy; however, it has unfriendly environmental impacts such as toxic emissions and health hazards; these impacts do not align with the recent orientation toward green industrial environments. Nowadays, researchers, practitioners, and designers focus on implementing sustainable EDM-based green environmental principles. Thus, this article presents an extensive overview of most of the enhancement and eco-friendly technologies for improving the efficiency of the EDM process (material removal rate, lower electrode wear ratio, and surface roughness) and lowering the environmental impacts. These enhancement technologies have been classified into four drivers. The advantages and limitations of each technology have been discussed. Then, the maturity of each technology has been estimated through technology readiness levels. Highlights EDM technology is in its maturity stage. The main research contributions in the last 10 years are on. The highest mature technologies are the cryogenic treatment, hybrid EDUVM, and PMEDM technologies. The CNT powder mixed EDM and the additive manufacturing technologies have been successfully applied in roughing processes and we expect more industrial applications. The high energy consumption with hybrid EDAM technology is nowadays limiting its maturity therefore further research is necessary to come to an industrially viable process.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"27 1","pages":"63 - 105"},"PeriodicalIF":2.7,"publicationDate":"2023-03-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"41872344","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"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 : 2023-03-04DOI: 10.1080/10910344.2023.2194968
Fengbiao Wang, Mathew Kuttolamadom
Abstract The helical milling hole process of quartz fiber reinforced polyimide composites (QFRP) aimed to remove high-strength fiber and low-strength resin through thermodynamic interaction. But the defects, especially delamination at hole outlet, were difficult inhabited because of heterogeneous and anisotropic of composite. A mechanics model of milling hole force of QFRP was established by considering the shearing force of single fiber and temperature. A liquid nitrogen (LN2) inner-cooling machining equipment was employed for cryogenic milling hole testes. Compared with the conventional dry milling hole, the processed composite surface morphologies, cutting temperature, and milling force were investigated at hole outlet in detail. The study results show the predict values of the established model are compared and verified through the experimental measurement. And the cryogenic coolant processes can improve the composite mechanics properties, milling forces, and cutting heat. The composite can be completely chip breaking in cryogenic cooling, and the burr and delamination are effectively inhabited at hole outlet. Meanwhile, the rapid decline of cutting force and lower interlamination bonding force problems can be solved by the cryogenic cooling cutting. And the fiber avoidance can be improved through the increased tangential force, and the fiber can be efficiency chip breaking under the bigger tangential force. In addition, LN2 cooling can inhabit the cutting high temperature and increase the bonding force, the delamination defect of composite can be adequately improved in cryogenic.
{"title":"Inhibition behavior of milling hole outlet defects inhibition on quartz fiber polyimide composite through LN2 inner cooling","authors":"Fengbiao Wang, Mathew Kuttolamadom","doi":"10.1080/10910344.2023.2194968","DOIUrl":"https://doi.org/10.1080/10910344.2023.2194968","url":null,"abstract":"Abstract The helical milling hole process of quartz fiber reinforced polyimide composites (QFRP) aimed to remove high-strength fiber and low-strength resin through thermodynamic interaction. But the defects, especially delamination at hole outlet, were difficult inhabited because of heterogeneous and anisotropic of composite. A mechanics model of milling hole force of QFRP was established by considering the shearing force of single fiber and temperature. A liquid nitrogen (LN2) inner-cooling machining equipment was employed for cryogenic milling hole testes. Compared with the conventional dry milling hole, the processed composite surface morphologies, cutting temperature, and milling force were investigated at hole outlet in detail. The study results show the predict values of the established model are compared and verified through the experimental measurement. And the cryogenic coolant processes can improve the composite mechanics properties, milling forces, and cutting heat. The composite can be completely chip breaking in cryogenic cooling, and the burr and delamination are effectively inhabited at hole outlet. Meanwhile, the rapid decline of cutting force and lower interlamination bonding force problems can be solved by the cryogenic cooling cutting. And the fiber avoidance can be improved through the increased tangential force, and the fiber can be efficiency chip breaking under the bigger tangential force. In addition, LN2 cooling can inhabit the cutting high temperature and increase the bonding force, the delamination defect of composite can be adequately improved in cryogenic.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"27 1","pages":"129 - 156"},"PeriodicalIF":2.7,"publicationDate":"2023-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42727180","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"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 : 2023-03-04DOI: 10.1080/10910344.2023.2194966
D. J. Hiran Gabriel, M. Parthiban, I. Kantharaj, N. Beemkumar
Abstract Cutting fluid is used in the field of engineering for hundreds of years, and it plays a critical role in component processing efficiency and surface quality. Water-based cutting fluid accounts for more than 90% of cutting fluid used. Conventional cutting fluids and conventional methods of coolant application are not sustainable, economical, and environmentally friendly. Cutting fluid application in large amounts also causes health issues for the operator. Researchers have developed and implemented sustainable methods like solid lubrication, cryogenic cooling, minimum quantity lubrication (MQL), and heat pipe-assisted cooling processes in the past two decades. The introduction of environmentally friendly machining techniques has considerably improved machinability in recent years. In the presented review, adverse effects of water based cutting fluids and sustainable alternative means to cut down on heat during machining and applying coolants were studied, and their pros and cons are listed. The review focuses on identifying the best available sustainable method that is economic, environmental, and is operator-friendly.
{"title":"A review on sustainable alternatives for conventional cutting fluid applications for improved machinability","authors":"D. J. Hiran Gabriel, M. Parthiban, I. Kantharaj, N. Beemkumar","doi":"10.1080/10910344.2023.2194966","DOIUrl":"https://doi.org/10.1080/10910344.2023.2194966","url":null,"abstract":"Abstract Cutting fluid is used in the field of engineering for hundreds of years, and it plays a critical role in component processing efficiency and surface quality. Water-based cutting fluid accounts for more than 90% of cutting fluid used. Conventional cutting fluids and conventional methods of coolant application are not sustainable, economical, and environmentally friendly. Cutting fluid application in large amounts also causes health issues for the operator. Researchers have developed and implemented sustainable methods like solid lubrication, cryogenic cooling, minimum quantity lubrication (MQL), and heat pipe-assisted cooling processes in the past two decades. The introduction of environmentally friendly machining techniques has considerably improved machinability in recent years. In the presented review, adverse effects of water based cutting fluids and sustainable alternative means to cut down on heat during machining and applying coolants were studied, and their pros and cons are listed. The review focuses on identifying the best available sustainable method that is economic, environmental, and is operator-friendly.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"27 1","pages":"157 - 207"},"PeriodicalIF":2.7,"publicationDate":"2023-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49192023","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Abstract Based on the modified KM (Kock–Mecking) model, a cutting constitutive model of AA7050-T7451 considering anisotropy is established in this article. With the aid of high-speed cutting FEM simulation and experiment, the micro-influence mechanism of anisotropy on high-speed cutting hardening of AA7050-T7451 was studied from three aspects: micro-morphology, residual strain, and plastic deformation. By analyzing the macro-micro correlation mechanism of dislocation density, work hardening, and cutting temperature, a “Three-Stage” model of work hardening is put forward. The results show that the work-hardening behavior of high-speed cutting AA7050-T7451 shows obvious anisotropic characteristics. And the work hardening degree is less than 0° and 90° at the material forming angle of 45°. At the 45° forming angle, the material dislocation density is the highest, and the grains are most prone to the dislocation slip. The macroscopic properties show that the microhardness of the material is small. The “Three-stage” model reveals the micro-evolution mechanism of work-hardening behavior. It is found that the dislocation density dominates the work-hardening behavior in stages I and II, and cutting temperature dominates the work-hardening behavior in stage III. The microhardness of the material increases sharply at first and then tends to be flat.
{"title":"Dislocation density evolution and hardening mechanism of AA7050-T7451 surface layer based on anisotropy","authors":"Zhenda Wang, Yongzhi Pan, Hui Wang, Zewen Zhang, X. Fu, Xiuhua Men","doi":"10.1080/10910344.2023.2194965","DOIUrl":"https://doi.org/10.1080/10910344.2023.2194965","url":null,"abstract":"Abstract Based on the modified KM (Kock–Mecking) model, a cutting constitutive model of AA7050-T7451 considering anisotropy is established in this article. With the aid of high-speed cutting FEM simulation and experiment, the micro-influence mechanism of anisotropy on high-speed cutting hardening of AA7050-T7451 was studied from three aspects: micro-morphology, residual strain, and plastic deformation. By analyzing the macro-micro correlation mechanism of dislocation density, work hardening, and cutting temperature, a “Three-Stage” model of work hardening is put forward. The results show that the work-hardening behavior of high-speed cutting AA7050-T7451 shows obvious anisotropic characteristics. And the work hardening degree is less than 0° and 90° at the material forming angle of 45°. At the 45° forming angle, the material dislocation density is the highest, and the grains are most prone to the dislocation slip. The macroscopic properties show that the microhardness of the material is small. The “Three-stage” model reveals the micro-evolution mechanism of work-hardening behavior. It is found that the dislocation density dominates the work-hardening behavior in stages I and II, and cutting temperature dominates the work-hardening behavior in stage III. The microhardness of the material increases sharply at first and then tends to be flat.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"27 1","pages":"107 - 128"},"PeriodicalIF":2.7,"publicationDate":"2023-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"48854191","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"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 : 2023-01-02DOI: 10.1080/10910344.2023.2194959
Shiyu Wei, P. Zou, J. Duan, K. Ehmann
Abstract The surface integrity of machined parts is critical to their in-service function, longevity and overall performance. The integrity of the surface is dominantly affected by the chip formation process that can be significantly altered and controlled, among other methods, by ultrasonic vibration assistance. This work will explore the integrity of surfaces generated in three-dimensional ultrasonic vibration-assisted turning (3D-UVAT). The integrity of the obtained workpiece surfaces will be systematically explored in terms of surface roughness, the microstructure of the surface obtained by heat-assisted turning, surface hardness and wettability. A comparative assessment with other surface generation methods, i.e., common turning (CT), one-dimensional (UVAT) and two-dimensional elliptical ultrasonic vibration-assisted turning (EUAT) is also given. The results show that 3D-UVAT can reduce the depth of surface damage and enhance the hydrophobicity of the surface while reducing surface roughness.
{"title":"Surface integrity in 3D ultrasonic vibration-assisted turning driven by two actuators","authors":"Shiyu Wei, P. Zou, J. Duan, K. Ehmann","doi":"10.1080/10910344.2023.2194959","DOIUrl":"https://doi.org/10.1080/10910344.2023.2194959","url":null,"abstract":"Abstract The surface integrity of machined parts is critical to their in-service function, longevity and overall performance. The integrity of the surface is dominantly affected by the chip formation process that can be significantly altered and controlled, among other methods, by ultrasonic vibration assistance. This work will explore the integrity of surfaces generated in three-dimensional ultrasonic vibration-assisted turning (3D-UVAT). The integrity of the obtained workpiece surfaces will be systematically explored in terms of surface roughness, the microstructure of the surface obtained by heat-assisted turning, surface hardness and wettability. A comparative assessment with other surface generation methods, i.e., common turning (CT), one-dimensional (UVAT) and two-dimensional elliptical ultrasonic vibration-assisted turning (EUAT) is also given. The results show that 3D-UVAT can reduce the depth of surface damage and enhance the hydrophobicity of the surface while reducing surface roughness.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"27 1","pages":"20 - 41"},"PeriodicalIF":2.7,"publicationDate":"2023-01-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"48333609","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"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 : 2023-01-02DOI: 10.1080/10910344.2023.2194958
Hao Li, Tao Chen, Hongbo Li, Yiwen Zhang
Abstract Conventional surface grinding can be divided into up grinding and down grinding according to rotation direction of spindle. Nevertheless, the effects and differences of ultrasonic vibration on the two machining methods have been less reported. The influence of ultrasonic vibration amplitude on cutting force, surface roughness and surface topography were investigated in this paper by conducting tangential and radial ultrasonic vibration assisted down/up grinding comparison experiments on SiC. The results showed that the grinding force of down grinding was less than that of up grinding in conventional grinding, while the surface roughness was greater than that of up grinding. The grinding forces of both down grinding and up grinding were reduced to different ratios after applying different ultrasonic vibration, while the surface roughness increased. The grinding force of up grinding decreased and then increased with the increase of amplitude, while the grinding force of down grinding kept decreasing and the surface roughness decreased. The reasons for the differences in cutting forces and surface quality between the two grinding methods after the application of ultrasonic vibration are discussed. By observing the surface morphology, the percentage of ductile area on the machined surface decreases and then increases with the increase of amplitude.
{"title":"Influence of ultrasonic vibration on machining quality of down/up grinding in ultrasonic vibration assisted grinding of silicon carbide","authors":"Hao Li, Tao Chen, Hongbo Li, Yiwen Zhang","doi":"10.1080/10910344.2023.2194958","DOIUrl":"https://doi.org/10.1080/10910344.2023.2194958","url":null,"abstract":"Abstract Conventional surface grinding can be divided into up grinding and down grinding according to rotation direction of spindle. Nevertheless, the effects and differences of ultrasonic vibration on the two machining methods have been less reported. The influence of ultrasonic vibration amplitude on cutting force, surface roughness and surface topography were investigated in this paper by conducting tangential and radial ultrasonic vibration assisted down/up grinding comparison experiments on SiC. The results showed that the grinding force of down grinding was less than that of up grinding in conventional grinding, while the surface roughness was greater than that of up grinding. The grinding forces of both down grinding and up grinding were reduced to different ratios after applying different ultrasonic vibration, while the surface roughness increased. The grinding force of up grinding decreased and then increased with the increase of amplitude, while the grinding force of down grinding kept decreasing and the surface roughness decreased. The reasons for the differences in cutting forces and surface quality between the two grinding methods after the application of ultrasonic vibration are discussed. By observing the surface morphology, the percentage of ductile area on the machined surface decreases and then increases with the increase of amplitude.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"27 1","pages":"1 - 19"},"PeriodicalIF":2.7,"publicationDate":"2023-01-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45495040","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"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 : 2023-01-02DOI: 10.1080/10910344.2023.2194964
A. Pratap, A. Gorodkova, K. Patra, Aleksandr A. Dyakonov
Abstract The objective of this work is to characterize the heat transfer and temperature generation into the workpiece during micro-slot grinding. A numerical model for predicting micro-grinding temperature is established based on the finite difference method (FDM). Workpiece volume is divided into small elementary sections and temperature in small sections near and away from the machining zone is calculated using thermo-physical model as well as validated by experimentally measured temperature using infrared technique. Temperature in micro-slot grinding increases during vertical insertion of the tool and becomes stable when the tool transverse in the feed direction. Simulation results show that transient heat transfer becomes dominant on increased feed rate values that result in an overall lowering of heat supply into the surface. Results also reveal that modification in the tool design has a significant impact on the reduction of workpiece temperature due to reduced contact length, reduced cutting forces, friction, and rubbing at the tool-workpiece interface. The proposed model is capable of solving transient problems in micro-slot grinding and is flexible to deal with different boundary conditions. This analysis will help in temperature prediction and establishing temperature reduction strategies that could potentially increase machining precision.
{"title":"Finite difference numerical modeling and experimental validation of workpiece surface temperature in micro-grinding","authors":"A. Pratap, A. Gorodkova, K. Patra, Aleksandr A. Dyakonov","doi":"10.1080/10910344.2023.2194964","DOIUrl":"https://doi.org/10.1080/10910344.2023.2194964","url":null,"abstract":"Abstract The objective of this work is to characterize the heat transfer and temperature generation into the workpiece during micro-slot grinding. A numerical model for predicting micro-grinding temperature is established based on the finite difference method (FDM). Workpiece volume is divided into small elementary sections and temperature in small sections near and away from the machining zone is calculated using thermo-physical model as well as validated by experimentally measured temperature using infrared technique. Temperature in micro-slot grinding increases during vertical insertion of the tool and becomes stable when the tool transverse in the feed direction. Simulation results show that transient heat transfer becomes dominant on increased feed rate values that result in an overall lowering of heat supply into the surface. Results also reveal that modification in the tool design has a significant impact on the reduction of workpiece temperature due to reduced contact length, reduced cutting forces, friction, and rubbing at the tool-workpiece interface. The proposed model is capable of solving transient problems in micro-slot grinding and is flexible to deal with different boundary conditions. This analysis will help in temperature prediction and establishing temperature reduction strategies that could potentially increase machining precision.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"27 1","pages":"42 - 62"},"PeriodicalIF":2.7,"publicationDate":"2023-01-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49469574","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"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 : 2022-11-02DOI: 10.1080/10910344.2023.2180751
Ganesan G., Ganesh Malayath, R. Mote
Abstract Ultra-precision cutting (UPC) is an advanced machining process capable of fabricating components with a surface finish and dimensional accuracy in the nanometer range. The cutting tool edge should possess ultra-sharpness and controlled waviness to bring off a higher degree of finish and accuracy. It also should have high hardness, toughness, thermal resistance and chemical inertness. As the cutting-edge radius is in order of nm, the edge characterization is always arduous. Profound knowledge regarding the wear patterns of the UPC tools is indispensable as it will affect the machining quality to a great extent. Hence, to employ a cutting tool for UPC operations, one should know the different variants of UPC and their characteristics, different tool materials and their properties, geometries and how it affects machining accuracy, various edge preparation method and characterization techniques and their limitations, associated measurement errors, tool wear patterns and processes to control the wear. These diverse areas have to be brought under a single roof to systematically choose the material, geometry, and fabrication method for UPC tools. This article provides a comprehensive review of the research related to cutting tools of UPC to understand and evaluate the current trends in the development of UPC tools. Graphical abstract
{"title":"A review of cutting tools for ultra-precision machining","authors":"Ganesan G., Ganesh Malayath, R. Mote","doi":"10.1080/10910344.2023.2180751","DOIUrl":"https://doi.org/10.1080/10910344.2023.2180751","url":null,"abstract":"Abstract Ultra-precision cutting (UPC) is an advanced machining process capable of fabricating components with a surface finish and dimensional accuracy in the nanometer range. The cutting tool edge should possess ultra-sharpness and controlled waviness to bring off a higher degree of finish and accuracy. It also should have high hardness, toughness, thermal resistance and chemical inertness. As the cutting-edge radius is in order of nm, the edge characterization is always arduous. Profound knowledge regarding the wear patterns of the UPC tools is indispensable as it will affect the machining quality to a great extent. Hence, to employ a cutting tool for UPC operations, one should know the different variants of UPC and their characteristics, different tool materials and their properties, geometries and how it affects machining accuracy, various edge preparation method and characterization techniques and their limitations, associated measurement errors, tool wear patterns and processes to control the wear. These diverse areas have to be brought under a single roof to systematically choose the material, geometry, and fabrication method for UPC tools. This article provides a comprehensive review of the research related to cutting tools of UPC to understand and evaluate the current trends in the development of UPC tools. Graphical abstract","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"26 1","pages":"923 - 976"},"PeriodicalIF":2.7,"publicationDate":"2022-11-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"43306533","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"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 : 2022-11-02DOI: 10.1080/10910344.2023.2181088
H. Tsai, W. Hsu, Ming You
Abstract Microbial fuel cells (MFCs), which generate low-pollution power through feeding organic trace minerals to bacteria, are crucial for applications involving energy recovery and environmental protection. In MFCs, electrodes critically influence the electrocatalytic process. In this study, an electrical-discharge-machining (EDM)-based surface treatment method for MFC electrodes was applied to a stainless-steel mesh (SSM), which was selected as an anode substrate. The experimental results indicated that EDM surface treatment formed a recast layer on the SSM anode surface. A few defects such as cracks and notches were observed after EDM surface treatment, which increased the surface and surface roughness of the SSM anode. To verify the effectiveness of the proposed EDM treatment, an Escherichia coli (HB101)-based single-chamber MFC system was fabricated, and the electrochemical activity of the EDM-treated anode was investigated through electrochemical analysis. The maximum power density of the MFCs equipped with the untreated SSM anode and the EDM-treated SSM anode under a pulse current of 1.5 A were 101.37 and 205.94 mW m−2, respectively. Thus, EDM surface treatment increased the power generated by the MFC by a factor of approximately 2. The proposed novel EDM surface treatment, therefore, has potential for development as a standard processing procedure for metal electrode substrates.
{"title":"Electrical discharge machining as a surface treatment process for improving the performance of microbial fuel cells","authors":"H. Tsai, W. Hsu, Ming You","doi":"10.1080/10910344.2023.2181088","DOIUrl":"https://doi.org/10.1080/10910344.2023.2181088","url":null,"abstract":"Abstract Microbial fuel cells (MFCs), which generate low-pollution power through feeding organic trace minerals to bacteria, are crucial for applications involving energy recovery and environmental protection. In MFCs, electrodes critically influence the electrocatalytic process. In this study, an electrical-discharge-machining (EDM)-based surface treatment method for MFC electrodes was applied to a stainless-steel mesh (SSM), which was selected as an anode substrate. The experimental results indicated that EDM surface treatment formed a recast layer on the SSM anode surface. A few defects such as cracks and notches were observed after EDM surface treatment, which increased the surface and surface roughness of the SSM anode. To verify the effectiveness of the proposed EDM treatment, an Escherichia coli (HB101)-based single-chamber MFC system was fabricated, and the electrochemical activity of the EDM-treated anode was investigated through electrochemical analysis. The maximum power density of the MFCs equipped with the untreated SSM anode and the EDM-treated SSM anode under a pulse current of 1.5 A were 101.37 and 205.94 mW m−2, respectively. Thus, EDM surface treatment increased the power generated by the MFC by a factor of approximately 2. The proposed novel EDM surface treatment, therefore, has potential for development as a standard processing procedure for metal electrode substrates.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"26 1","pages":"1003 - 1018"},"PeriodicalIF":2.7,"publicationDate":"2022-11-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45601783","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"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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