Article
Optics
Lei Zhang, Qizhi Zhao, Cheng Fan
Summary: In this paper, a continuous TIF (cTIF) is proposed to solve the dwell time in deterministic polishing, and an optimized algorithm is used to simulate and calculate the residual errors in the actual polishing process, achieving good convergence results.
Article
Engineering, Mechanical
Zili Zhang, Chi Fai Cheung, Chunjin Wang, Jiang Guo
Summary: Fluid jet polishing (FJP) is widely used in precision molding and optical components, but the understanding of surface morphology evolution on the micro scale is incomplete. This paper develops a physical model combining computational fluid dynamics (CFD) simulation and kinetic analysis to predict surface morphology and roughness after FJP. Different parameters are considered in the model and a series of polishing experiments are conducted to validate it.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2023)
Article
Engineering, Multidisciplinary
Chunjin Wang, Zili Zhang, Chi Fai Cheung, Wang Luo, Yee Man Loh, Yanjun Lu, Lingbao Kong, Shixiang Wang
Summary: This paper presents a novel maskless fluid jet polishing (MFJP) technique to improve the quality of optical structured surfaces, and experimental investigations demonstrate its technical feasibility on sinusoidal and V-groove structures. The results indicate that MFJP can significantly enhance the surface quality of optical structured surface and possess high form maintainability under certain conditions.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2022)
Article
Engineering, Mechanical
Jiahui Li, Weihao Ma, Xi Hou, Yun Zhang
Summary: This study presents an ultra-smooth surface polishing technology based on elastic material removal, and proposes a multiscale contact area analysis model to study the material removal process and predict the removal profile. The reliability of the model is verified through experiments, and the influence of experimental parameters on the material removal rate is explained.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2023)
Article
Engineering, Industrial
Zhong-Chen Cao, Ming Wang, Shengqin Yan, Chenyao Zhao, Haitao Liu
Summary: Fluid jet polishing (FJP) is a widely used technology for ultra-precision polishing of complex optical components. This study investigates the influence of polishing parameters on the damage characteristics and surface quality of optical glass through experiments and numerical simulations. A damage control strategy is proposed based on the understanding of material removal mechanism. The results provide theoretical support for equipment upgrade and process optimization of FJP.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2023)
Article
Engineering, Manufacturing
C. J. Wang, C. F. Cheung, L. T. Ho, Y. M. Loh
Summary: A novel fluid line-jet polishing (FLJP) process was developed, which can achieve higher polishing efficiency and better material removal uniformity compared to traditional fluid jet polishing. Experimental results indicate that FLJP has a higher material removal rate and superior surface quality under the same polishing conditions.
JOURNAL OF MANUFACTURING PROCESSES
(2021)
Article
Optics
Z. I. L. I. Zhang, Chi fai Cheung, C. H. U. N. J. I. N. Wang, Lai ting Ho, J. I. A. N. G. Guo
Summary: In this paper, multi-jet polishing (MJP) is proposed to control the mid-spatial frequency (MSF) error in optical surface polishing. The results demonstrate that MJP has excellent ripple error reduction ability, and the path spacing and nozzle orientation angle significantly affect the MSF error of the polished surface.
Article
Chemistry, Physical
Zili Zhang, Chunjin Wang, Wule Zhu, Jiang Guo, Chi Fai Cheung
Summary: This study focused on the polishing of structured array surfaces using fluid jet polishing (FJP) technique. Computational fluid dynamics (CFD) simulation was combined to investigate the effect of abrasive size and jet pressure on form maintainability. The removal process and surface generation were analyzed to optimize the polishing parameters. A surface form maintenance strategy was proposed, which effectively achieved high form accuracy and excellent surface quality. Experimental validation confirmed the effectiveness of the strategy, paving the way for polishing structured array surfaces with precise form control.
APPLIED SURFACE SCIENCE
(2023)
Article
Engineering, Manufacturing
Junyuan Feng, Zhenyu Zhang, Shiqiang Yu, Xin Chen, Dong Wang, Qinming Gu, Chunchen Zhou, Tianyu Zhang, Bingxin Liu
Summary: A novel multiphase jet (MPJ) polishing method was devised to polish the inside of heat pipes with intricate structures, achieving the desired weight reduction and avoiding the possibility of powders and burrs falling. The material removal rate for MPJ polishing is 1.64 mg/min to polish a heat pipe with a length of 400 mm and a length to diameter ratio of 87:1. The surface roughness of the inlet after polishing is improved by 23 times compared to the pristine surface, providing new insights into how to polish and fabricate high-performance components with complex structures.
ADDITIVE MANUFACTURING
(2023)
Article
Materials Science, Multidisciplinary
Chunjin Wang, Yee Man Loh, Chi Fai Cheung, Xiaoliang Liang, Zili Zhang, Lai Ting Ho
Summary: This paper presents a multi-jet polishing (MJP) method for post-processing additively manufactured (AMed) surfaces, particularly those with complex surface geometries. Through systematic polishing tests on 316L stainless steel (SS) prepared by powder bed fusion, the polishing performance and the effect of key parameters are evaluated. The results demonstrate the effectiveness of MJP in obtaining nanometric surface roughness on AMed 316L SS, indicating the potential wide application of MJP for post-processing complex AMed surfaces.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Article
Optics
Kuiping Wan, Songlin Wan, Chen Jiang, Chaoyang Wei, Jianda Shao
Summary: This paper finds that the fluid jet polishing (FJP) method has a significant advantage in removing the residual periodic ripples in sub-aperture polishing, and the mathematical model validates the effectiveness of the sparse bi-step raster path (BSRP).
Article
Chemistry, Physical
Oliver McRae, T. S. Ramakrishnan, James C. Bird
Summary: This study shows that traditional pore doublet models lose accuracy in describing complex fluid flow at the interface of immiscible fluids in low aspect-ratio pores. However, a minimal 1D pore doublet model may be sufficient to model global dynamics when the pore diameter and length are comparable.
JOURNAL OF COLLOID AND INTERFACE SCIENCE
(2022)
Article
Computer Science, Artificial Intelligence
Ruoxin Wang, Mei Na Cheng, Yee Man Loh, Chunjin Wang, Chi Fai Cheung
Summary: This study developed a robust surface roughness prediction model based on ensemble learning with a genetic algorithm (ELGA) for predicting surface roughness in multi-jet polishing (MJP) of 3D-printed stainless steel. Experimental results showed that the ELGA model outperformed six other machine learning-based models.
EXPERT SYSTEMS WITH APPLICATIONS
(2022)
Article
Engineering, Multidisciplinary
Hao Zhang, Xiaodong Zhang, Zexiao Li, Peng Wang, Zhipeng Guo
Summary: In this study, an active fluid jet (AFJ) polishing technology was developed for removing diamond turning marks. A simulation model was developed to analyze the material removal and fluid-structure interaction in the AFJ polishing process. Experimental results showed the optimal combination of parameters for removing turning marks, and the changes in the surface profiles and microtopography helped determine the suitable material removal rate for eliminating turning marks without destroying the surface form. The AFJ polishing method was proven to enable form-preserving post-treatment of diamond-turned surfaces.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2022)
Article
Engineering, Mechanical
Ming Feng, Yang Lei, Zhixiang Chen, Xianglei Zhang, Xizhang Chen, Youliang Wang
Summary: In this study, the feasibility and characteristics of polishing elliptical elements using a doughnut-shaped MCF polishing tool were investigated through experimental research. The results showed that the middle portion of the polishing tool had the best material removal ability, and different polishing slurries had varying effects on surface roughness and glossiness. Additionally, the working gap, revolution speed, and polishing time also influenced the polishing results. The microstructure of the MCF polishing tool after polishing revealed even distribution of abrasive particles grabbed by ferric clusters, with alpha-celluloses interleaved between the clusters.
Article
Engineering, Chemical
Jun Zhao, YongChao Xiang, Cheng Fan
Summary: The traditional polishing method for the inner wall of a tube has limitations in tool size and geometric constraints. This paper proposes a new method called soft abrasive rotating jet polishing (SARJP) to overcome these limitations and optimize the polishing process. By combining the Taguchi method and response surface technique, the speed and quality of the optimization process were improved. Mathematical statistics and graph tools were used to assess the influence of various factors on the roughness of the inner wall of the tube.
Article
Automation & Control Systems
Lei Zhang, Chen Ding, Cheng Fan, Qian Wang, Kejun Wang
Summary: This paper studies the surface processing technology of curved surfaces and develops a five-axis CNC polishing machine tool. The effects of different polishing paths on the surface quality and polishing efficiency of the metal shell of a mobile phone are studied through experiments, and the best polishing path is found.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Engineering, Manufacturing
Cheng Fan, Kun Xu, Lei Zhang, Qiang Yuan, Qian Wang, Kejun Wanga, Lining Sun
Summary: This paper presents the development of an integrated polishing and in-situ measurement machine tool with seven-axis and five-linkage for manufacturing and measuring complex curved surfaces. Kinematic analysis and inverse kinematic solutions are used to calculate the motion of each axis based on the tool location of the complex curved surface. The paper also develops forward kinematic solutions, processing of measured data, and calculation algorithms for machining allowance, which are verified through polishing experiments.
MACHINING SCIENCE AND TECHNOLOGY
(2022)
Article
Engineering, Manufacturing
Yang Li, Fu-Sheng Liang, Lei Lu, Cheng Fan
Summary: Feedrate scheduling is crucial for CNC machining to improve efficiency and precision. This study proposes a general feedrate scheduling method for non-uniform rational B-splines tool paths, which can flexibly adjust acceleration and deceleration and handle both geometry and high-order drive constraints.
ADVANCES IN MANUFACTURING
(2023)
Article
Materials Science, Coatings & Films
Zhao Wang, Zhelun Ma, Tao Chen, Cheng Fan, Tianbiao Yu, Ji Zhao
Summary: The influence of different AWJP parameters on the surface integrity of Inconel 718 alloy was investigated. The results showed that pump pressure and standoff distance had the greatest impact on surface integrity, while flowrate and traverse speed had a smaller effect. The AWJP-treated workpiece formed a footprint width of 3.0-4.3 mm, with the maximum surface roughness occurring at a pump pressure of 300 MPa. The thickness of the stress layer was approximately 100-180 μm, and the maximum compressive residual stress was larger than 1100 MPa. Pump pressure had a significant effect on microhardness, and the maximum hardness increased by more than 20%.
SURFACE & COATINGS TECHNOLOGY
(2023)
Article
Engineering, Industrial
Ashwani Pratap, Shuntaro Yamato, Anthony Beaucamp
Summary: To reduce process time, a hybrid tool that combines a stiff grinding tool and a shape adaptive grinding (SAG) tool has been proposed. The material removal achieved by the hybrid tool is equivalent to using the stiff grinding and SAG tools in sequence. This hybrid tool can obtain a smoother surface on BK7 glass compared to the stiff grinding tool under similar processing conditions.
CIRP ANNALS-MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Industrial
Wu-Le Zhu, Wei Gao, Fang Han, Bing-Feng Ju, Yuan-Liu Chen, Anthony Beaucamp
Summary: Compliant polishing using elastic tools can achieve ultraprecision surface quality on freeform workpieces. An analytical model and adaptive strategies are used to address the complex polishing mechanics in thin-walled parts and predict the interaction mechanics during polishing. Experimental results show high accuracy and achieve compliant polishing of precise removal consistency below 0.5 μm on a thin-walled freeform workpiece.
CIRP ANNALS-MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Manufacturing
Linqiang Gong, Cheng Fan, Zhi Shen, Zhang Chen, Lei Zhang
Summary: Traditional surface processing measures for free-form surface parts are unable to distinguish the curvature and characteristics of different areas, making machining non-uniform. In order to solve these problems, this study proposes a discrete partition algorithm for simplifying the free-form surface parts. Additionally, an optimal machining path planning algorithm based on genetic algorithm principles is proposed to improve machining efficiency. Simulation analysis confirms the effectiveness of the proposed surface partition algorithm in improving machining accuracy.
JOURNAL OF MANUFACTURING PROCESSES
(2023)
Article
Materials Science, Multidisciplinary
Binbin Meng, Tao Chen, Lei Zhang, Cheng Fan
Summary: This study investigates the feasibility of using monocrystal SiC as a cutting tool material and proposes crystal plane parameters corresponding to rake/flank faces. Large-scale molecular dynamics simulations are conducted to perform single point diamond turning machining on monocrystal Cu and monocrystal Si. An in-depth analysis of the suitability of monocrystal SiC tools in SPDT machining is carried out. The results show that monocrystal SiC has excellent potential as a tool material, although material deformation and removal processes differ from those observed with monocrystal diamond tools.
MATERIALS TODAY COMMUNICATIONS
(2023)
Article
Engineering, Mechanical
Guang Xia, Zirui Wang, Qingyu Yao, Ping Sun, Huaijun Guan, Yongguang Wang, Cheng Fan, Da Bian, Dong Zhao, Yongwu Zhao
Summary: This paper proposes a novel material removal rate (MRR) model for aluminum chemical mechanical polishing (CMP) based on molecular-scaled removal mechanism, micro-contact force equilibrium theory, chemical reaction kinetics and diffusion effects. The model considers the lubricant effect on the removal rate at low polishing pressure and clarifies the nonlinear dependence of removal rate on lubricant concentration, oxidizer concentration, and abrasive concentration. The theoretical predictions show qualitative agreement with the experimental results.
Article
Engineering, Manufacturing
Cheng Fan, Xingfeng Wang, Kaixuan Liu, Yigang Chen, Fusheng Liang, Zhao Wang, Jun Zhao
Summary: This paper presents a new manufacturing method of low-temperature-assisted electrorheological polishing to improve the surface quality of foldable acrylate intraocular lenses (IOLs). The effects of temperature on the mechanical properties and material removal mechanism of IOLs were studied systematically. A new low temperature-assisted electrorheological polishing system was designed, and the results showed that low-temperature-assisted electrorheological polishing is an effective method for fabricating foldable acrylate IOLs with high efficiency and quality.
JOURNAL OF MANUFACTURING PROCESSES
(2023)
Article
Engineering, Manufacturing
Cheng Fan, Cao-Yang Xue, Jun Zhao, Wei Jiang, Wen-Ge Han, Lei Zhang, Li-Ning Sun
Summary: This study proposes a new sharpening process for grinding miniature scalpels on a four-axis machine tool. A parameter calibration method and contour-based error compensation method are introduced to achieve accurate adjustments to the edge shape following grinding, improving the surface processing quality of miniature scalpels.
ADVANCES IN MANUFACTURING
(2023)
Article
Engineering, Manufacturing
Lei Lu, Jiang Han, Lian Xia, Cheng Fan, Haijun Liu, Shan Chen
Summary: In order to improve the application of the parametric curve tool path in surface machining, a method for generating arc-length parameterized toolpaths based on short-line toolpaths is proposed. The method involves planning the short-line tool path using commercial CAM software and extracting the machining tool path with smooth continuous features. The feasibility of the method is verified and two smooth arc-length parametric toolpaths are generated.
INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING
(2023)
Article
Chemistry, Multidisciplinary
Xinyue Li, Lei Lu, Cheng Fan, Fusheng Liang, Lining Sun, Lei Zhang
Summary: Researchers have shown great interest in robots with openness and flexibility in the field of surface machining. A redundant degree of freedom exists in 6-DOF robot machining, which requires the optimization of the tool axis vector. A strategy called Redundancy Optimization for Minimum Joint trajectory (ROMJ) is proposed to achieve the optimal design of the tool axis vector trajectory.
APPLIED SCIENCES-BASEL
(2023)
Article
Engineering, Mechanical
Cheng Fan, Kaixuan Liu, Yongguang Wang, Lei Zhang, Lining Sun
Summary: This paper investigates the deformation and material removal mechanism of acrylate intraocular lenses (IOLs), providing a foundation for ultra-precision polishing of this flexible material. Indentation experiments using an atomic force microscope (AFM) reveal a significant surface effect under nano-scale indentation. The loading curve deviates from the P-h(2) relationship to some extent with changing loading rates. The material exhibits a pronounced size effect, with nano-hardness decreasing from 7.7 MPa to 6.4 MPa within a depth range of 300-800 nm. Nano-scratch tests demonstrate a decrease in friction coefficient as the normal load reduces, indicating a transition from inclusion elastic deformation to interfacial friction within the system.
ACTA MECHANICA SINICA
(2023)