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| 1 | Advances in fabrication of ceramic corundum abrasives based on sol–gel process显示文摘Corundum abrasives with good chemical stability can be fabricated into various free abrasives and bonded abrasive tools that are widely used in the precision machining of various parts.However,these abrasives cannot satisfy the machining requirements of difficult-to-machine materials with high hardness,high strength,and strong wearing resistance.Although superhard abrasives can machine the above-mentioned materials,their dressing and manufacturing costs are high.By contrast,ceramic corundum abrasives fabricated by sol–gel method is a costeffective product between conventional and superhard abrasives.Ceramic corundum abrasives exhibit self-sharpening and high toughness.In this review,the optimization methods of ceramic corundum abrasive properties are introduced from three aspects:precursor synthesis,particle shaping,and sintering.Firstly,the functional mechanism of seeds and additives on the microstructural and mechanical properties of abrasives is analyzed.Specifically,seeds can reduce the phase transition temperature and improve fracture toughness.The grain size and uniformly dense structure can be controlled by applying an appropriate amount of multicomponent additives.Then,the urgent need of engineering application and machinability of special shape ceramic corundum abrasives is reviewed,and three methods of abrasive shaping are summarized.The micromold replication technique is highly advanced and can be used to prepare functional abrasives.Additionally,the influence of a new sintering method,namely,two-step sintering technique,on the microstructural and mechanical performance of ceramic corundum abrasives is summarized.Finally,the challenge and developmental trend of the optimization of ceramic corundum abrasives are prospected. | Baoteng HUANG Changhe LI Yanbin ZHANG Wenfeng DING Min YANG Yuying YANG Han ZHAI Xuefeng XU Dazhong WANG Sujan DEBNATH Muhammad JAMIL Hao Nan Li Hafiz Muhammad ALI Munish Kumar GUPTA Zafar SAID | 2021 | Chinese Journal of Aeronautics2021，34，6： | 11 |
| 2 | Cryogenic minimum quantity lubrication machining: from mechanism to application显示文摘Cutting fluid plays a cooling-lubrication role in the cutting of metal materials.However,the substantial usage of cutting fluid in traditional flood machining seriously pollutes the environment and threatens the health of workers.Environmental machining technologies,such as dry cutting,minimum quantity lubrication(MQL),and cryogenic cooling technology,have been used as substitute for flood machining.However,the insufficient cooling capacity of MQL with normal-temperature compressed gas and the lack of lubricating performance of cryogenic cooling technology limit their industrial application.The technical bottleneck of mechanical-thermal damage of difficult-to-cut materials in aerospace and other fields can be solved by combining cryogenic medium and MQL.The latest progress of cryogenic minimum quantity lubrication(CMQL)technology is reviewed in this paper,and the key scientific issues in the research achievements of CMQL are clarified.First,the application forms and process characteristics of CMQL devices in turning,milling,and grinding are systematically summarized from traditional settings to innovative design.Second,the cooling-lubrication mechanism of CMQL and its influence mechanism on material hardness,cutting force,tool wear,and workpiece surface quality in cutting are extensively revealed.The effects of CMQL are systematically analyzed based on its mechanism and application form.Results show that the application effect of CMQL is better than that of cryogenic technology or MQL alone.Finally,the prospect,which provides basis and support for engineering application and development of CMQL technology,is introduced considering the limitations of CMQL. | Mingzheng LIU Changhe LI Yanbin ZHANG Qinglong AN Min YANG Teng GAO Cong MAO Bo LIU Huajun CAO Xuefeng XU Zafar SAID Sujan DEBNATH Muhammad JAMIL Hafz Muhammad ALI Shubham SHARMA | 2021 | Frontiers of Mechanical Engineering2021，16，4： | 8 |
| 3 | Milling Force Model for Aviation Aluminum Alloy: Academic Insight and Perspective Analysis显示文摘Aluminum alloy is the main structural material of aircraft,launch vehicle,spaceship,and space station and is processed by milling.However,tool wear and vibration are the bottlenecks in the milling process of aviation aluminum alloy.The machining accuracy and surface quality of aluminum alloy milling depend on the cutting parameters,material mechanical properties,machine tools,and other parameters.In particular,milling force is the crucial factor to determine material removal and workpiece surface integrity.However,establishing the prediction model of milling force is important and difficult because milling force is the result of multiparameter coupling of process system.The research progress of cutting force model is reviewed from three modeling methods:empirical model,finite element simulation,and instantaneous milling force model.The problems of cutting force modeling are also determined.In view of these problems,the future work direction is proposed in the following four aspects:(1)high-speed milling is adopted for the thin-walled structure of large aviation with large cutting depth,which easily produces high residual stress.The residual stress should be analyzed under this particular condition.(2)Multiple factors(e.g.,eccentric swing milling parameters,lubrication conditions,tools,tool and workpiece deformation,and size effect)should be considered comprehensively when modeling instantaneous milling forces,especially for micro milling and complex surface machining.(3)The database of milling force model,including the corresponding workpiece materials,working condition,cutting tools(geometric figures and coatings),and other parameters,should be established.(4)The effect of chatter on the prediction accuracy of milling force cannot be ignored in thin-walled workpiece milling.(5)The cutting force of aviation aluminum alloy milling under the condition of minimum quantity lubrication(mql)and nanofluid mql should be predicted. | Zhenjing Duan Changhe Li Wenfeng Ding Yanbin Zhang Min Yang Teng Gao Huajun Cao Xuefeng Xu Dazhong Wang Cong Mao Hao Nan Li Gupta Munish Kumar Zafar Said Sujan Debnath Muhammad Jamil Hafiz Muhammad Ali | 2021 | Chinese Journal of Mechanical Engineering2021，34，1： | 7 |
| 4 | Comparative assessment of force,temperature,and wheel wear in sustainable grinding aerospace alloy using biolubricant显示文摘The substitution of biolubricant for mineral cutting fluids in aerospace material grinding is an inevitable development direction,under the requirements of the worldwide carbon emission strategy.However,serious tool wear and workpiece damage in difficult-to-machine material grinding challenges the availability of using biolubricants via minimum quantity lubrication.The primary cause for this condition is the unknown and complex influencing mechanisms of the biolubricant physicochemical properties on grindability.In this review,a comparative assessment of grindability is performed using titanium alloy,nickel-based alloy,and high-strength steel.Firstly,this work considers the physicochemical properties as the main factors,and the antifriction and heat dissipation behaviours of biolubricant in a high temperature and pressure interface are comprehensively analysed.Secondly,the comparative assessment of force,temperature,wheel wear and workpiece surface for titanium alloy,nickel-based alloy,and high-strength steel confirms that biolubricant is a potential replacement of traditional cutting fluids because of its improved lubrication and cooling performance.High-viscosity biolubricant and nano-enhancers with high thermal conductivity are recommended for titanium alloy to solve the burn puzzle of the workpiece.Biolubricant with high viscosity and high fatty acid saturation characteristics should be used to overcome the bottleneck of wheel wear and nickel-based alloy surface burn.The nano-enhancers with high hardness and spherical characteristics are better choices.Furthermore,a different option is available for high-strength steel grinding,which needs low-viscosity biolubricant to address the debris breaking difficulty and wheel clogging.Finally,the current challenges and potential methods are proposed to promote the application of biolubricant. | Xin CUI Changhe LI Yanbin ZHANG Wenfeng DING Qinglong AN Bo LIU Hao Nan LI Zafar SAID Shubham SHARMA Runze LI Sujan DEBNATH | 2023 | Frontiers of Mechanical Engineering2023，18，1： | 3 |
| 5 | Minimum quantity lubrication machining of aeronautical materials using carbon group nanolubricant: From mechanisms to application显示文摘It is an inevitable trend of sustainable manufacturing to replace flood and dry machining with minimum quantity lubrication(MQL)technology.Nevertheless,for aeronautical difficult-tomachine materials,MQL couldn’t meet the high demand of cooling and lubrication due to high heat generation during machining.Nano-biolubricants,especially non-toxic carbon group nano-enhancers(CGNs)are used,can solve this technical bottleneck.However,the machining mechanisms under lubrication of CGNs are unclear at complex interface between tool and workpiece,which characterized by high temperature,pressure,and speed,limited its application in factories and necessitates in-depth understanding.To fill this gap,this study concentrates on the comprehensive quantitative assessment of tribological characteristics based on force,tool wear,chip,and surface integrity in titanium alloy and nickel alloy machining and attempts to answer mechanisms systematically.First,to establish evaluation standard,the cutting mechanisms and performance improvement behavior covering antifriction,antiwear,tool failure,material removal,and surface formation of MQL were revealed.Second,the unique film formation and lubrication behaviors of CGNs in MQL turning,milling,and grinding are concluded.The influence law of molecular structure and micromorphology of CGNs was also answered and optimized options were recommended by considering diverse boundary conditions.Finally,in view of CGNs limitations in MQL,the future development direction is proposed,which needs to be improved in thermal stability of lubricant,activity of CGNs,controllable atomization and transportation methods,and intelligent formation of processing technology solutions. | Xin CUI Changhe LI Wenfeng Ding Yun CHEN Cong MAO Xuefeng XU Bo LIU Dazhong WANG Hao Nan LI Yanbin ZHANG Zafar SAID Sujan DEBNATH Muhammad JAMIL Hafiz Muhammad ALI Shubham SHARMA | 2022 | Chinese Journal of Aeronautics2022，35，11： | 3 |
| 6 | Biological Stability of Water-Based Cutting Fluids:Progress and Application显示文摘The application of cutting fluid in the field of engineering manufacturing has a history of hundreds of years,and it plays a vital role in the processing efficiency and surface quality of parts.Among them,water-based cutting fluid accounts for more than 90%of the consumption of cutting fluid.However,long-term recycling of water-based cutting fluid could easily cause deterioration,and the breeding of bacteria could cause the cutting fluid to fail,increase manufacturing costs,and even endanger the health of workers.Traditional bactericides could improve the biological stability of cutting fluids,but they are toxic to the environment and do not conform to the development trend of low-carbon manufacturing.Low-carbon manufacturing is inevitable and the direction of sustainable manufacturing.The use of nanomaterials,transition metal complexes,and physical sterilization methods on the bacterial cell membrane and genetic material could effectively solve this problem.In this article,the mechanism of action of additives and microbial metabolites was first analyzed.Then,the denaturation mechanism of traditional bactericides on the target protein and the effect of sterilization efficiency were summarized.Further,the mechanism of nanomaterials disrupting cell membrane potential was discussed.The effects of lipophilicity and the atomic number of transition metal complexes on cell membrane penetration were also summarized,and the effects of ultraviolet rays and ozone on the destruction of bacterial genetic material were reviewed.In other words,the bactericidal performance,hazard,degradability,and economics of various sterilization methods were comprehensively evaluated,and the potential development direction of improving the biological stability of cutting fluid was proposed. | Lizhi Tang Yanbin Zhang Changhe Li Zongming Zhou Xiaolin Nie Yun Chen Huajun Cao Bo Liu Naiqing Zhang Zafar Said Sujan Debnath Muhammad Jamil Hafiz Muhammad Ali Shubham Sharma | 2022 | Chinese Journal of Mechanical Engineering2022，35，1： | 2 |
| 7 | Mechanical behavior and semiempirical force model of aerospace aluminum alloy milling using nano biological lubricant显示文摘Aerospace aluminum alloy is the most used structural material for rockets,aircraft,spacecraft,and space stations.The deterioration of surface integrity of dry machining and the insufficient heat transfer capacity of minimal quantity lubrication have become the bottleneck of lubrication and heat dissipation of aerospace aluminum alloy.However,the excellent thermal conductivity and tribological properties of nanofluids are expected to fill this gap.The traditional milling force models are mainly based on empirical models and finite element simulations,which are insufficient to guide industrial manufacturing.In this study,the milling force of the integral end milling cutter is deduced by force analysis of the milling cutter element and numerical simulation.The instantaneous milling force model of the integral end milling cutter is established under the condition of dry and nanofluid minimal quantity lubrication(NMQL)based on the dual mechanism of the shear effect on the rake face of the milling cutter and the plow cutting effect on the flank surface.A single factor experiment is designed to introduce NMQL and the milling feed factor into the instantaneous milling force coefficient.The average absolute errors in the prediction of milling forces for the NMQL are 13.3%,2.3%,and 7.6%in the x-,y-,and z-direction,respectively.Compared with the milling forces obtained by dry milling,those by NMQL decrease by 21.4%,17.7%,and 18.5%in the x-,y-,and z-direction,respectively. | Zhenjing DUAN Changhe LI Yanbin ZHANG Min YANG Teng GAO Xin LIU Runze LI Zafar SAID Sujan DEBNATH Shubham SHARMA | 2023 | Frontiers of Mechanical Engineering2023，18，1： | 0 |
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