Article
Engineering, Multidisciplinary
JunFeng Xiao, Feng Guo, Chen Zhang, Xiao Chen, JianGuo Zhang, JianFeng Xu
Summary: The study shows that magnetic field assistance can significantly improve the cutting performance of nickel-based superalloy, including improving chip morphology, reducing cutting force oscillation, improving surface quality, reducing the concavity-convexity of the machined surface's fan-shaped area, and improving hardness and ductility.
SCIENCE CHINA-TECHNOLOGICAL SCIENCES
(2022)
Article
Engineering, Aerospace
Shijin LU, Junjie ZHANG, Zengqiang LI, Jianguo ZHANG, Xiaohui WANG, Alexander HARTMAIER, Jianfeng XU, Yongda YAN, Tao SUN
Summary: In this study, the influence of cutting path on the machinability of SiCp/Al composite in multi-step ultra-precision diamond cutting was investigated. The number of cutting steps was found to have a substantial impact on particle-tool interactions and machined surface quality.
CHINESE JOURNAL OF AERONAUTICS
(2021)
Article
Engineering, Multidisciplinary
Lars Schoenemann, Oltmann Riemer, Bernhard Karpuschewski, Per Schreiber, Heinrich Klemme, Berend Denkena
Summary: The research has found that ultra-precision cutting based on digital surface twins can accurately predict surface features and characteristics, thus supporting the development of tool offset compensation methods and improving productivity.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2022)
Article
Automation & Control Systems
Guilin Zhuang, Wenjun Zong, Yifu Tang
Summary: This study shows that minimum quantity lubrication (MQL) can reduce cutting temperature and tool wear. Low viscosity cutting fluid helps wetting at the tool-chip contact interface, reducing friction. MQL can also slow down the graphitization of diamond, effectively reducing tool wear.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Review
Green & Sustainable Science & Technology
Yan Jin Lee, Hao Wang
Summary: Optical-grade surfaces can be achieved on metals and ceramics by precise control of diamond cutting tools. However, researchers are seeking innovative techniques to further improve precision manufacturing efficiency. This review provides systematic evaluations of the energy consumed and energy savings of these techniques, aiming to categorize them as sustainable green technology. The article also proposes future research directions to identify optimal sustainable manufacturing methods.
INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING-GREEN TECHNOLOGY
(2023)
Article
Engineering, Manufacturing
Zhanwen Sun, Sujuan Wang, Suet To, Shijun Xu, Guangyu Guo
Summary: Ultra-precision diamond cutting is a promising method for fabricating precision parts of titanium alloys. This study proposes an analytical specific cutting energy (SCE) model that takes into account various factors such as material microstructures, spring back, size effect, cutting edge effect, temperature evolution, and tool-chip frictional states. The results show that the cutting edge effect and spring back contribute to a high SCE at small undeformed chip thickness. The study also suggests an energy-oriented machining parameters optimization method to minimize the SCE in UPDC of titanium alloys.
JOURNAL OF MANUFACTURING PROCESSES
(2023)
Article
Engineering, Manufacturing
Ruitao Zhang, Zhanfeng Wang, Zengqiang Li, Shilei Wu, Junjie Zhang, Tao Sun
Summary: This study introduces a novel approach using the diamond dynamic micro tensile strength theory to establish a grinding factor prediction model for any position on the flank face of rounded diamond cutting tools. Experimental investigations reveal pronounced anisotropy on the flank of the diamond tool during mechanical grinding, and the modified grinding factor model shows excellent agreement with the observed change in the material removal rate.
JOURNAL OF MANUFACTURING PROCESSES
(2023)
Article
Materials Science, Multidisciplinary
Zhuoxuan Zhuang, Hanheng Du, Wai Sze Yip, Tengfei Yin, Zejia Zhao, Zhiwei Zhu, Suet To
Summary: In this study, a novel micro and nano-cutting device with complex-axis is developed to overcome the challenge of generating multi-scale cutting motions with high accuracy. The device consists of a customized designed linear voice coil motor and a piezoelectric actuated flexure-hinge mechanism. The device has been optimized using magnetic field simulation and validated through experiments using a force sensor, and it can generate microstructures with high accuracy and flexibility in ultraprecision machining.
MATERIALS & DESIGN
(2023)
Article
Materials Science, Ceramics
Chen Junyun, Sun Lei, Jin Tianye, Luo Kun, Zhao Zhisheng, Tian Yongjun
Summary: By adding layered BN at the intersection of cBN grains, a tough Lt-cBN material with high fracture toughness and excellent cutting performance has been developed.
JOURNAL OF INORGANIC MATERIALS
(2022)
Article
Chemistry, Analytical
Chen-Yang Zhao, Chi-Fai Cheung, Wen-Peng Fu
Summary: The paper presents an investigation into cutting strategy for the optimization of machining parameters in ultra-precision machining of polar microstructures used for optical precision measurement. Critical machining parameters affecting surface generation and quality were studied through cutting simulations and experiments. The study includes theoretical modeling, image processing, and an experimental investigation of cutting tool geometry, depth of cut, and groove spacing on polar microstructures.
Article
Engineering, Manufacturing
Linhe Sun, Wenhong Duan, Hanqiang Wu, Minghan Chen, Jiang Zeng, Yongbo Wu, Yuhan Chen
Summary: Theoretical and experimental investigations have shown that using straight-nosed cutting tools in the single-point diamond turning of ZnSe aspheric surfaces can significantly improve machining performance and surface integrity. The use of straight-nosed cutting tools reduces cut thickness, residual feed marks, and improves surface roughness. It also reduces work adhesion and micro-edge chipping, resulting in extended tool life.
JOURNAL OF MANUFACTURING PROCESSES
(2023)
Article
Automation & Control Systems
Yuanyuan Ding, Xiaoting Rui, Yu Chang, Hanjing Lu, Yiheng Chen, Jianguo Ding, Adeel Shehzad, Gangli Chen, Junjie Gu
Summary: In this paper, a dynamic model of the rotational component of the ultra-precision fly cutting machine tool is established using the finite element method. The influence of the deformation of the fly cutting head and tool holders on the tool tip displacement is validated through modal and machining tests. Three optimization schemes for the fly cutting head and tool holder are proposed and analyzed, and the scheme with the highest performance improvement is selected.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Automation & Control Systems
Yuanyuan Ding, Xiaoting Rui, Yiheng Chen, Hanjing Lu, Yu Chang, Wei Wei
Summary: This paper establishes a simulation model of surface stripes in ultra-precision flycutting machining and analyzes the influences of various factors. The accuracy of the model is verified by comparing with experimental results. The model can be used to optimize the cutting process and provide cost and time savings.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Review
Automation & Control Systems
Junhong Han, Yanbing Chen, Jianpeng Wang, Guoqing Zhang, Haitao Wang
Summary: This paper reviews the principles, applications, and limitations of molecular dynamics (MD) simulation in studying the surface generation mechanism in ultra-precision cutting. It summarizes relevant studies on different factors influencing the surface generation process, such as cutting thickness, tool parameters, cutting parameters, cutting force and temperature, and crystal orientation.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Automation & Control Systems
Yujie Liu, Hao Tong, Guodong Liu, Yong Li, Qifeng Tan
Summary: This paper focuses on the tool wear issue when turning quartz glass with diamond tools with certain edge radius. A cutting model is established to estimate the damaged layer thickness on the machined surface, and the undeformed chips shape considering the strain rate is obtained by numerical simulation method. Experimental results show that the lateral crack depth calculated by the model has the same variation pattern as the surface roughness Sk value, and good consistency is achieved when the feed rate is ranging 1-4 mu m/r with a cutting depth of 2 mu m.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Chemical
Yexiang Fu, Fuwang Zhao, Zejia Zhao, Hui Tang, Suet To, Ching-Hsiang Cheng
Summary: This study reports a method that combines hydrothermal synthesis with ultraprecision machining to fabricate a hierarchical coated surface, improving its hydrophobicity. The experimental results show that the hierarchical surface has a larger contact angle and better water droplet bouncing behavior, indicating excellent water repellency.
JOURNAL OF ADHESION SCIENCE AND TECHNOLOGY
(2023)
Article
Engineering, Chemical
Clement Kehinde Ajani, Zhiwei Zhu, Da-Wen Sun
Summary: In this study, a conjugate modelling approach was used to investigate the momentum, heat, mass transport, and structural deformation during vacuum cooling of steamed bread. The results showed that the three-parameter Maxwell model accurately described the viscoelastic behavior of the bread, and the model predictions were accurate for moisture variation and areal shrinkage. Sensitivity analysis revealed that the deformation model was more sensitive to water transport parameters, particularly the hydrous compressibility factor.
JOURNAL OF FOOD ENGINEERING
(2023)
Article
Green & Sustainable Science & Technology
Wai Sze Yip, Suet To
Summary: This study combines social network analysis (SNA) and principal component analysis (PCA) to prioritize Ultra-precision machining (UPM) factors based on their combined characteristics. It uses SNA results as input for PCA to generate principal components, which are then combined into multiple characteristic performance indexes (MPCI). Few case studies validate the effectiveness of adjustments in UPM factors with high MPCI on machining outcomes. The study contributes to providing a comprehensive reference for prioritizing UPM factors and developing practical machining strategies.
INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING-GREEN TECHNOLOGY
(2023)
Article
Chemistry, Physical
Dan Xu, Hong Zhong, Mitch Guijun Li, Sandy Suet, Lin Lu
Summary: Solar-driven steam generation is an attractive solution to the freshwater and energy crisis, utilizing abundant solar energy and undrinkable water resources with low environmental impact. To achieve practical solar evaporation, efficient solar absorbers with broad spectrum response, high heat conversion, low cost, and stability are crucial. Additionally, preventing salt crystal accumulation on the evaporation surface is vital for maintaining long-term evaporation efficiency.
Article
Engineering, Manufacturing
Zi-Hui Zhu, Peng Huang, Suet To, Li-Min Zhu, Zhiwei Zhu
Summary: A fast-tool-servo-controlled shear-thickening micropolishing method is proposed for removing undesired surface diffraction on diamond-turned microstructured surfaces. The method allows for controllable material removal by adjusting the gap width and achieves improved surface quality.
INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE
(2023)
Article
Materials Science, Multidisciplinary
Zhuoxuan Zhuang, Hanheng Du, Wai Sze Yip, Tengfei Yin, Zejia Zhao, Zhiwei Zhu, Suet To
Summary: In this study, a novel micro and nano-cutting device with complex-axis is developed to overcome the challenge of generating multi-scale cutting motions with high accuracy. The device consists of a customized designed linear voice coil motor and a piezoelectric actuated flexure-hinge mechanism. The device has been optimized using magnetic field simulation and validated through experiments using a force sensor, and it can generate microstructures with high accuracy and flexibility in ultraprecision machining.
MATERIALS & DESIGN
(2023)
Article
Engineering, Mechanical
Tengfei Yin, Hanheng Du, Guoqing Zhang, Wei Hang, Suet To
Summary: This paper investigates the formation mechanism of surface waviness in ultra-precision grinding. A dynamics model of the aerostatic bearing wheel spindle is developed to analyze its vibration characteristics. Surface waviness formation models are established considering wheel spindle vibration (WSV) and non-uniform wheel topography (NWT) as the origins of waviness. Grinding experiments are conducted to validate the models. The study provides useful insights for optimizing grinding conditions to enhance surface quality and tribological properties.
TRIBOLOGY INTERNATIONAL
(2023)
Article
Chemistry, Analytical
Xin Li, Yinggang Wang, Hongyu Chen, Wenhong Zhao, Qianfa Deng, Tengfei Yin, Suet To, Zhe Sun, Xi Shen, Wei Hang, Julong Yuan
Summary: In this study, polyurethane, damping cloth, and non-woven fabric were selected as polishing pads. The HPMJ conditioning technology was found to be better than traditional diamond conditioning in terms of keeping the polishing pad surface clean and preventing the hole structure from being blocked. Additionally, the HPMJ conditioned polishing pad had a longer service life and a more stable material removal rate.
Article
Engineering, Manufacturing
Zhanwen Sun, Sujuan Wang, Suet To, Shijun Xu, Guangyu Guo
Summary: Ultra-precision diamond cutting is a promising method for fabricating precision parts of titanium alloys. This study proposes an analytical specific cutting energy (SCE) model that takes into account various factors such as material microstructures, spring back, size effect, cutting edge effect, temperature evolution, and tool-chip frictional states. The results show that the cutting edge effect and spring back contribute to a high SCE at small undeformed chip thickness. The study also suggests an energy-oriented machining parameters optimization method to minimize the SCE in UPDC of titanium alloys.
JOURNAL OF MANUFACTURING PROCESSES
(2023)
Article
Automation & Control Systems
Peizheng Li, Sujuan Wang, Suet To, Zhanwen Sun, Jie Jiao, Shijun Xu
Summary: This study proposes a semi-ductile diamond milling method that can produce high-quality microstructured surfaces with high efficiency by fully considering the curvature variation, microstructure geometry characteristics, and machining parameters. By establishing a semi-ductile machining model and the relationship between machining parameters and fragmentation length, determining the dynamically changing tool trajectory, and conducting a comparison experiment, it is demonstrated that the method has high quality and efficiency in creating microstructures on hard and brittle materials.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Mechanical
Changlin Liu, Suet To, Xuexiang Sheng, Jianfeng Xu
Summary: This paper explores the formation mechanism of crystal defects in single-crystal silicon during elliptical vibration cutting (EVC) using molecular dynamics simulation. The study finds that the cutting stage in EVC greatly influences the surface morphology, including elastic recovery and side flow. The preferred slip motion during subsurface damage formation is distinct in the extrusion and shear stage. The influence of cutting temperature and speed on crystal defects formation is also investigated, revealing the increase in proportion of Shockley partial dislocations at elevated temperature and the suppression of crystal defects generation with higher speed ratio.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2023)
Article
Biochemistry & Molecular Biology
C. H. Wong, E. A. Buntov, W. S. Yip, S. To, M. B. Guseva, A. F. Zatsepin
Summary: Through Monte Carlo simulation, we investigated the kink structures in free-standing carbon nanowires under high temperatures. Our study found that short carbon chains exhibit disordered kink structures at high temperatures, which may enhance the chemisorption of negatively charged atoms and provide important insights for the development of high-temperature chemisorption materials.
INTERNATIONAL JOURNAL OF MOLECULAR SCIENCES
(2023)
Article
Automation & Control Systems
Yan-Ning Fang, Xiaonan Pu, Suet To, Bernard Hon, Li-Min Zhu, Zhiwei Zhu
Summary: To overcome the limitations of current piezo-actuated triaxial fast tool servos (FTSs), a novel normal-stressed electromagnetic triaxial FTS with a compact structure and high resonant frequency is proposed. It achieves triaxial motions in the range of hundreds of micrometers and utilizes a single armature for decoupled and noncontact driving forces. The prototype of the triaxial FTS shows excellent agreement with the design target in terms of static and dynamic performances. The system is further enhanced with a linear active disturbance rejection control and an iterative learning scheme for fast and accurate trajectory tracking. By fabricating a hexagonal spherical microlens array, the triaxial FTS demonstrates its capability with a high level of spatial accuracy and good surface quality.
IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS
(2023)
Article
Chemistry, Multidisciplinary
Changlin Liu, Wai Sze Yip, Suet To, Bolong Chen, Jianfeng Xu
Summary: This article investigates the deformation mechanisms of CdTe during nano-grinding through molecular dynamics (MD) simulation. The results show that the dominant grinding mechanism changes from elastic deformation to ploughing and cutting as the grinding depth increases. The grain size affects the transition from ploughing to cutting and the generation of subsurface damage and dislocations.
Article
Engineering, Chemical
Louis Luo Fan, Wai Sze Yip, Zhanwan Sun, Baolong Zhang, Suet To
Summary: This study investigates the effect of substrate-to-filament distances on coating thickness, diamond purity, coating grain size, and ZrO2 machining performance during HFCVD. The results indicate that smaller substrate-to-filament distances lead to decreased grain size and coating thickness, resulting in improved machining quality for diamond-coated milling tools.
