Article
Automation & Control Systems
Bin Xu, Tao Feng, Yong-chang Xiao, Xiao-yu Wu, Lian-yu Fu, Hang Zhao, Jian-guo Lei, Chun-yang Zhao
Summary: In this study, a method combining micro-EDM and micro milling cutter was proposed to process micro-stepped holes. By using a worn micro milling cutter as the tool electrode and performing multi-stage micro-EDM on YG8 cemented carbide, the successful machining of micro-stepped holes was achieved.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Materials Science, Ceramics
Xian Wu, Kai Zeng, Li Zhong, Jianyun Shen, Liang Li
Summary: Cemented carbides undergo a reduction in surface hardness and the formation of a porous oxide layer after oxidation, leading to the development of a hybrid micro-milling operation. This operation has been shown to decrease tool wear and cutting force, making it a potential high-efficiency machining method for cemented carbide.
CERAMICS INTERNATIONAL
(2021)
Article
Engineering, Mechanical
Jay Airao, Hreetabh Kishore, Chandrakant K. Nirala
Summary: The parts produced by additive manufacturing (AM) need post-processing operations before direct applications. Micro-milling is a common post-processing operation for micromachining of selective laser melted (SLM) Ti6Al4V. The micro-milling performances for SLM Ti6Al4V and wrought Ti6Al4V are compared, and the outcomes, including tool wear and surface characteristics, are examined. SLM Ti6Al4V produces less adhesive tool wear and boundary layer formation, but more tool abrasion and surface roughness compared to wrought Ti6Al4V.
Article
Materials Science, Multidisciplinary
Xin Tong, Jianing Shen, Shuai Su
Summary: This study investigated a cemented carbide ball-end milling cutter with surface modifications to improve cutting performance and enhance titanium alloys' machining quality by preparing micro-textures on the surface and optimizing the parameters through regression analysis.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2021)
Article
Chemistry, Physical
Eduardo L. Silva, Sergio Pratas, Miguel A. Neto, Cristina M. Fernandes, Daniel Figueiredo, Rui F. Silva
Summary: Diamond-coated cobalt-cemented carbide micro-end mills were studied for micro-machining applications. The diamond coatings featured a multilayer architecture of sub-microcrystalline and nanocrystalline layers and exhibited high adhesion to the tool substrates. The machining performance and wear behavior of the coated tools were evaluated, showing a correlation between coating structure and properties.
Article
Engineering, Mechanical
Rebecka Lindvall, Juan Manuel Bello Bermejo, Belen Camara Herrero, Sebastian Siren, Lena Magnusson Aberg, Susanne Norgren, Rachid M'Saoubi, Volodymyr Bushlya, Jan-Eric Stahl
Summary: Stricter regulations on emissions and higher demands on engine performance drive the automotive industry to replace gray cast iron with compacted graphite iron (CGI). However, CGI is more difficult to machine due to its higher wear resistance and strength. This study examines the milling of CGI with cemented carbide tools, and finds that the wear mechanisms involve chemical wear of the coating, diffusional and mechanical wear of the carbide layer, and rapid wear of the substrate. The presence of oxide inclusions reduces the wear rate by preventing CGI adhesion.
Article
Materials Science, Multidisciplinary
Tao Zheng, Qinghua Song, Yicong Du, Zhanqiang Liu
Summary: This paper investigates the wear process and wear mechanism of micro-milling cutters. By designing experiments and observing and analyzing the different wear states of micro-milling cutters, failure criteria for the cutters are proposed, and the forms and mechanisms of wear are revealed. The results indicate that the formulation of a wear standard for micro-milling cutters requires comprehensive consideration of various factors.
Article
Engineering, Manufacturing
Zhiqiang Liang, Yuchao Du, Yue Ma, Zhipeng Su, Rui Chen, Hao Yuan, Tianfeng Zhou, Xibin Wang
Summary: In this study, the mechanism of milling-grinding combined machining of cemented carbide was analyzed, and a new PCD micro end mill structure was designed. By establishing a mathematical model, the fabrication of a new micro mill with a certain helix flute width was realized. The experimental results showed that the new micro mill had improved surface quality and wear resistance, making it suitable for high-quality and high-efficiency machining.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Materials Science, Multidisciplinary
Xuemei Liu, Zhantao Liang, Haibin Wang, Zhi Zhao, Chao Liu, Hao Lu, Xiaoyan Song
Summary: In this study, WCoB was added to ultra-coarse cemented carbides to improve the oxidation- and wear-resistance at elevated temperatures. The addition of WCoB enhanced wear resistance by restraining the WC grains, and also inhibited oxidation by forming liquid B2O3 in the oxidation layer and sharing stress with WC matrix.
INTERNATIONAL JOURNAL OF REFRACTORY METALS & HARD MATERIALS
(2022)
Article
Materials Science, Multidisciplinary
Ming-Hua Pang, Yi-Kun Hu, Shuai-Jie Zhai, Qiu-Chen Zhang, Li-Jie Ma, Qi-Gao Feng
Summary: This study investigates the correlation mechanism between high temperature oxidation and tribological properties of cemented carbide. Experimental results indicate that the surface roughness and oxidation degree increase with the heating temperature, leading to a decrease in friction coefficient and an increase in surface wear quantity. The effect of heating temperature on the friction coefficient is more complex under cutting fluid lubrication conditions.
INTERNATIONAL JOURNAL OF REFRACTORY METALS & HARD MATERIALS
(2022)
Article
Engineering, Mechanical
Pengfei Ding, Xianzhen Huang, Shangjie Li, Chengying Zhao, Xuewei Zhang
Summary: The development of micro-milling technology has enabled high-precision machining of complex and small-size parts in modern manufacturing. This study proposes a micro-milling mechanical model that considers the change of tool wear, tool runout, and chip separation status with cutting time, using the improved Gated Recurrent Unit with Multi-objective Dandelion Optimizer and mathematical modeling. The accuracy of the model is verified through experiments on Al6061. Bayesian updating method is used to invert the posterior distribution of process parameters, and the High-dimensional Model Representation with the Stochastic configuration network method efficiently realizes the reliability calculation of machining system parameters. The research evaluates the influence of cutting parameter changes on the extreme value of micro-milling force and provides analytical methods and theoretical guidance for safe processing.
MECHANICAL SYSTEMS AND SIGNAL PROCESSING
(2023)
Article
Engineering, Mechanical
A. R. F. Oliveira, L. R. R. da Silva, V Baldin, M. P. C. Fonseca, R. B. Silva, A. R. Machado
Summary: Nickel-based superalloys are widely used in the aerospace industry for their high-temperature performance, but their properties make them difficult to machine, requiring rigorous control of surface integrity and residual stresses to prevent premature failures. Residual stresses, whether thermal or mechanical, are present in all mechanical components and can be influenced by tool wear, machining forces, and cutting temperatures.
Article
Materials Science, Multidisciplinary
B. D. Beake, L. Isern, J. L. Endrino, T. W. Liskiewicz, X. Shi
Summary: Micro-impact is a novel accelerated test method for assessing coating durability under repetitive contact, concentrating impact-induced stresses close to the interfaces in coating systems for high sensitivity. It has the potential to speed up the pace of coating system selection for durability under highly loaded repetitive contacts in various applications.
Article
Chemistry, Analytical
Tongshun Liu, Qian Wang, Weisu Wang
Summary: In this study, a nonlinear mechanistic cutting force model considering the comprehensive effect of cutting-edge radius and tool wear on the micro-milling force is constructed for micro-milling tool wear monitoring. A stepwise offline optimization approach is proposed to estimate the multiple parameters of the model. Experiments show that, compared with the linear model, the nonlinear model has significantly improved cutting force prediction accuracy and tool wear monitoring accuracy.
Article
Engineering, Mechanical
Suman Saha, Sankha Deb, Partha Pratim Bandyopadhyay
Summary: This study investigates the correlation between changes in edge features and reduction in outer diameter to more accurately calculate tool wear in micro-milling. Analytical expressions for different wear scenarios are derived and validated through sustainable MQL-assisted micro-milling. The diameter reduction is established as a reliable variable for drawing tool life curves.
Article
Engineering, Multidisciplinary
Giacomo Maculotti, Gianfranco Genta, Danilo Quagliotti, Maurizio Galetto, Hans N. Hansen
Summary: Modern smart and intelligent manufacturing increasingly relies on highly engineered surfaces and quasi-free form geometries, necessitating fast and informative measurement tools for quality control, leading to the adoption of optical surface topography measuring instruments. Despite disturbances in surface topography measurements by optical instruments, a Gaussian process regression-based method has been proposed to identify and correct measurement disturbances simultaneously, offering a formal and practical approach to managing different types of disturbances.
QUALITY AND RELIABILITY ENGINEERING INTERNATIONAL
(2022)
Article
Chemistry, Physical
Chong Chen, Fan Zhang, Yang Zhang, Xin Xiong, Bing-Feng Ju, Hailong Cui, Yuan Liu Chen
Summary: By establishing a visualization model using COMSOL (R) Multiphysics, this study successfully investigated the quantitative relationship between the parameters of single-pulse femtosecond laser and the geometries of ablated monocrystalline silicon micro-holes. The results demonstrated that the visualization model can effectively predict the ablation results of single-pulse femtosecond laser, allowing for precise femtosecond laser ablation on monocrystalline silicon without the need for trial-and-errors.
APPLIED SURFACE SCIENCE
(2022)
Article
Materials Science, Ceramics
Hongjun Xia, Guolong Zhao, Yang Zhang, Liang Li, Ning He, Hans Norgaard Hansen
Summary: Laser-induced controllable oxidation coupled with micro-milling (LOMM) is a feasible method for machining difficult materials like TiB2-TiC ceramic composites. The oxidation behavior of the material under laser irradiation and the influence of laser parameters and gas atmospheres were investigated. Results showed that both laser parameters and oxygen content had significant impacts on oxidation behavior.
CERAMICS INTERNATIONAL
(2022)
Article
Materials Science, Multidisciplinary
Dongya Li, Yang Zhang, Yu Liu, Francesco Regi, Mads Emil Brix Doest, Guido Tosello
Summary: This paper presents a process chain of injection moulding of microstructures for mass production of plastic parts with optically functional surfaces. The microstructures of orthogonally textured modules were fabricated using micro milling on the tool surfaces and replicated to the plastic components through micro injection moulding. The contrast between the modules was quantified and optimized for the maximum contrast on the surfaces of the tools and replicas.
Article
Engineering, Industrial
Yang Zhang, Shuo Shan, Flavia D. Frumosu, Matteo Calaon, Wenzhen Yang, Yu Liu, Hans N. Hansen
Summary: An in-process monitoring procedure based on computer vision inspection and deep learning is proposed for quality monitoring in soft tooling injection moulding. The proposed method can detect multiple types of injection moulding defects and measure the geometrical dimensions of the part simultaneously while quantifying the uncertainty.
CIRP ANNALS-MANUFACTURING TECHNOLOGY
(2022)
Article
Optics
Chong Chen, Chong Kuong Ng, Fan Zhang, Xin Xiong, Bing-Feng Ju, Yang Zhang, Hans Norgaard Hansen, Yuan-Liu Chen
Summary: This study used femtosecond laser ablation to achieve surfaces with nanometric finish. Different parameters were investigated, and a mathematical model was established to study the formation mechanism of ablated surface characteristics. Experiments verified the effectiveness of this method.
OPTICS AND LASER TECHNOLOGY
(2022)
Article
Computer Science, Interdisciplinary Applications
Flavia Dalia Frumosu, Macarena Mendez Ribo, Shuo Shan, Yang Zhang, Murat Kulahci
Summary: This study proposes an online monitoring system for additive manufacturing (AM) to improve automation. The system uses sensor-generated data to detect detachment errors between built parts and the build platform, preventing material and time loss.
INTERNATIONAL JOURNAL OF COMPUTER INTEGRATED MANUFACTURING
(2023)
Article
Engineering, Electrical & Electronic
Dongya Li, Haodong Hong, Xinhu Sun, Yang Zhang, Yu Liu
Summary: Electrohydrodynamic (EHD) printing is an effective method for high-resolution two-dimensional patterning. The latest research focuses on 3D structure fabrication of various materials. Traditional EHD 3D printing of polymers faces challenges in filament deposition and stacking accuracy. This study develops an external field-assisted EHD printing process for polymer materials, achieving high aspect ratios for micro-scale 3D structures.
JOURNAL OF MICROMECHANICS AND MICROENGINEERING
(2023)
Article
Materials Science, Multidisciplinary
Dongya Li, Yang Zhang, Guido Tosello, Xinquan Zhang, Dennis Neo, Yu Liu
Summary: This paper demonstrates a voxel-based method to pattern consistently oriented microstructures onto 3D surfaces. The feasibility of the method is validated and an optimization routine is determined. Moreover, the method is proved suitable for batch production of 3D functional surfaces by micro injection moulding through over 15,000 injection moulding cycles.
Article
Materials Science, Multidisciplinary
H. Fang, E. Hovad, Y. Zhang, D. Juul Jensen
Summary: Segmentation of spots in diffraction images is crucial for accurate grain mapping in 3D. We applied an automatic instance segmentation deep learning network based on Mask R-CNN to find spots in LabDCT images. By combining virtual noise-free images and noise-only images, we trained the network to perform better than conventional methods, resulting in improved grain reconstruction.
MATERIALS CHARACTERIZATION
(2023)
Review
Engineering, Industrial
Myka Mae Duran, Gafaru Moro, Yang Zhang, Aminul Islam
Summary: This review paper discusses the challenges and solutions in 3D printing elastomers for medical devices. It introduces the state-of-the-art 3D printing techniques for silicone and polyurethane materials, and discusses the manufacturing challenges and current solutions for elastomers. The review paper provides research direction for the future development of 3D printing elastomers for patient-specific medical devices.
ADVANCES IN INDUSTRIAL AND MANUFACTURING ENGINEERING
(2023)
Article
Engineering, Electrical & Electronic
Jun Ren, Dongya Li, Yang Zhang, Wenzhen Yang, Heng-yong Nie, Yu Liu
Summary: This paper presents a laser-induced selective activation (LISA) process for creating complex conductive patterns on polyimide substrates. The LISA process enhances the stability of plated metallic structures and exhibits superior mechanical stability and high resolution.
ACS APPLIED ELECTRONIC MATERIALS
(2022)