Article
Engineering, Industrial
Zhipeng Cui, Chunyu Zhang, Haijun Zhang, Guo Li, Liqiang Wu, Wenjun Zong, Kai Du
Summary: This research discusses the wear characteristics and wear law of pointed diamond tools in V-groove processing, as well as the model of cutting stress distribution and cutting force. The wear of pointed diamond tools is reflected in the increase of cutting edge radius, with a high wear rate initially that gradually decreases.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2022)
Article
Engineering, Industrial
Weihai Huang, Kodai Nagayama, Jiwang Yan
Summary: This study investigates the fabrication of spherical and hexagonal microlens arrays on calcium fluoride (CaF2) using diamond turning. The study demonstrates that microcracks tend to be generated during the cutting process, especially when cutting along specific directions. By reducing the maximum undeformed chip thickness and using a depth-offsetting segment cutting method, high-quality microlens arrays without surface cracking can be achieved. This study proves the feasibility of fabricating high-quality freeform microstructured surfaces on CaF2 and other soft-brittle materials through diamond turning.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2023)
Article
Materials Science, Multidisciplinary
Hanheng Du, Zhiwei Zhu, Zuankai Wang, Suet To
Summary: This study proposes a novel piezoelectrically actuated cutting system for fabricating high-aspect-ratio and hierarchical micro/nanostructure arrays. The mechanical structure is designed based on the circular flexure hinge, and a finite element model is established to analyze its resonant frequencies and mode shapes. The effectiveness and flexibility of the proposed cutting system are demonstrated by fabricating micro/nanostructure arrays with varying features.
MATERIALS & DESIGN
(2023)
Article
Chemistry, Analytical
Senbin Xia, Ziqiang Yin, Cheng Huang, Songtao Meng
Summary: This paper proposes a new machining method to manufacture Hexagonal cube corner retroreflectors (HCCRs) on 3-linear-axis ultraprecision lathes. By optimizing the dedicated diamond tool and toolpaths, high-quality large-area HCCRs are successfully machined. This research work will reduce the production threshold and costs, which is important for promoting the industrial application of HCCRs.
Article
Green & Sustainable Science & Technology
Zejia Zhao, Tengfei Yin, Suet To, Zhiwei Zhu, Zhuoxuan Zhuang
Summary: This paper investigates the evolution of material removal energy in ultraprecision machining and finds that the total material removal energy decreases with increasing feedrate, but the maximum material removal energy increases. The study also discusses the differences in material removal energy in different regions and the formation mechanism and effects of cleavage fracture.
JOURNAL OF CLEANER PRODUCTION
(2022)
Article
Engineering, Industrial
Ziqi Chen, Qian Yu, Keita Shimada, Peng Liu, Yupeng He, Yao Hu, Xibin Wang, Tianfeng Zhou, Masayoshi Mizutani
Summary: This paper proposes an ultrasonic-assisted ultra-precision planing (UAUP) method for the fabrication of blazed gratings. The relationship between processing parameters and grating characteristic dimensions was established, and the feasibility of the UAUP method was verified.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2023)
Article
Engineering, Electrical & Electronic
K. Manjunath, Suman Tewary, Neha Khatri, Kai Cheng
Summary: This paper discusses the ultraprecision machining process in manufacturing, exploring how artificial intelligence and digital solutions can solve practical issues and discussing future research directions.
Article
Engineering, Industrial
Yuhan Chen, Linhe Sun, Yongbo Wu
Summary: Using straight-nosed cutting tools can reduce cut thickness, cutting force, and heat flux density, leading to decreased tool wear and smoother machined surface, enhancing cutting efficiency.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2022)
Article
Multidisciplinary Sciences
Yanming Zhang, Zhen Zhang, Yi Zhang, Denghua Liu, Jie Wu, Yu Huang, Guojun Zhang
Summary: Magnetic controlled laser induced plasma micro-machining (MC-LIPMM) can effectively improve the machining characteristics of silicon materials, while cavitation bubbles show an apparent negative impact on surface morphology.
JOURNAL OF ADVANCED RESEARCH
(2021)
Article
Engineering, Manufacturing
Farooq Ahmed, Furqan Ahmad, S. Thirumalai Kumaran, Mohd Danish, Rendi Kurniawan, Saood Ali
Summary: This research focuses on the development of a micro-milling strategy to suppress burr formation during machining through the use of LN2 jet. Cryogenic treatment enhances the mechanical properties of the workpiece surface, reducing excessive plastic flow and resulting in a significant decrease in burr formation. Experimental results show improved machining quality in terms of cutting forces, chip morphology, and surface roughness.
JOURNAL OF MANUFACTURING PROCESSES
(2023)
Article
Green & Sustainable Science & Technology
Jiayi Zhang, Yan Jin Lee, Hao Wang
Summary: The study validates the influence of the Rehbinder effect on AA6061-T6 microcutting and characterizes its impact on surface texture transformation. It is found that the Rehbinder effect results in softer surfaces compared to conventional machining, with different grain types and textures observed. The differences are attributed to induced stress states during microcutting, exemplified through numerical simulations considering the reduction in material fracture toughness.
INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING-GREEN TECHNOLOGY
(2021)
Article
Engineering, Multidisciplinary
Xiaoming Liu, Deping Yu, Dongsheng Chen, Shengyuan Yang, Yana Wen, Yu Xiao
Summary: This paper presents a novel self-tuned ultrasonic elliptical vibration cutting (SUEVC) technique for high-efficient ductile-regime machining of brittle materials, achieving a 30% increase in machining efficiency while maintaining similar surface roughness and crack-free surfaces.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2021)
Article
Materials Science, Multidisciplinary
Yunfa Guo, Yan Jin Lee, Yu Zhang, Anastassia Sorkin, Sergei Manzhos, Hao Wang
Summary: Magneto-plasticity refers to the phenomenon where a weak magnetic field can alter the plasticity of materials, and it offers a potential solution for enhancing ductile-mode cutting of brittle materials. This study demonstrates the susceptibility of non-magnetic single-crystal calcium fluoride to the magneto-plastic effect and confirms the influence of magneto-plasticity on the material's plastic deformation and crack propagation. The research also reveals an anisotropic influence of the magnetic field on the cutting direction and crystal orientation, and an analytical model is derived to describe this influence.
JOURNAL OF MATERIALS SCIENCE & TECHNOLOGY
(2022)
Article
Chemistry, Physical
Jingzhen Shao, Xu Liang, Ying Lin, Shimao Wang, Zanhong Deng, Gang Meng, Xiaodong Fang
Summary: In this study, the relationship between crystal plane and damage characteristics was analyzed by conducting laser damage experiments on three different crystal planes (100), (110) and (111) of CaF2 crystals. The formation mechanism of surface morphology of (111), (110) and (100) crystal planes was summarized by analyzing the relationship among crystal plane, cleavage plane and slip plane.
APPLIED SURFACE SCIENCE
(2022)
Review
Engineering, Manufacturing
Weihai Huang, Jiwang Yan
Summary: Brittle materials are widely used in optics, optoelectronics, and semiconductors. Ultraprecision machining of brittle materials can improve their functional performance and lifespan. This paper provides a comprehensive overview of recent advances in ultraprecision machining of soft-brittle materials, comparing different machining methods and analyzing their effects on tool-workpiece interactions. The paper also identifies challenges in engineering applications and provides solutions and guidelines for future research and development.
INTERNATIONAL JOURNAL OF EXTREME MANUFACTURING
(2023)
Article
Automation & Control Systems
Jing Hong, Lin Zhang, Zhiyu Zhang, Hu Huang, Jiwang Yan
Summary: A comparative study was conducted on mechanical polishing (MP) and laser polishing (LP) as methods for improving the quality of laser-nitrided surfaces. The results showed that LP significantly reduced surface roughness and achieved remarkable improvements in surface quality.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Manufacturing
Lin Zhang, Yusuke Sato, Jiwang Yan
Summary: This manuscript proposes a novel adaptive control points sampling strategy to improve form accuracy and retain as many micro surface features as possible. By adjusting the sampling stepovers between control points to adapt to surface profile variation, the proposed method constrains interpolation error within tolerance and eliminates issues of insufficient/excessive control points in the machining area. Compared to the constant sampling method, the form error of the proposed method is reduced by about 35% in both theoretical predictions and experimental measurements with the same number of control points. This technique provides a new route for allocating control points in FTS diamond turning to achieve high form accuracy and machining efficiency in the fabrication of freeform optics.
JOURNAL OF ADVANCED MECHANICAL DESIGN SYSTEMS AND MANUFACTURING
(2023)
Article
Engineering, Industrial
Weihai Huang, Jiwang Yan
Summary: Ultrasonic vibration cutting (UVC) is a promising technology for processing hard-brittle materials in a ductile mode. This study used cyclic nanoindentation to reveal the mechanism of UVC in monocrystalline silicon (Si) and found that cyclic loading promotes silicon amorphization and decreases the threshold for phase transition. Furthermore, the critical cutting depth for brittle-to-ductile transition and the degree of amorphization in cutting chips increase in UVC compared to conventional cutting.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2023)
Article
Chemistry, Multidisciplinary
Mingming Cui, Hu Huang, Lin Zhang, Jiwang Yan
Summary: In this study, a new nanosecond laser pulling method is proposed to fabricate micro-nano structures on metallic glasses. The formation mechanism and evolution of the micro-nano bulge are investigated, and various micro-nano structures are successfully created on the MG surface, affecting the surface optical diffraction. Overall, this study provides a highly flexible and controllable method for the fabrication of micro-nano structures on MGs.
Article
Materials Science, Coatings & Films
Hongyang Zhang, Yongfeng Qian, Lin Zhang, Minqiang Jiang, Hu Huang, Jiwang Yan
Summary: Laser carbonization of Zr-based metallic glass surface immersed in graphite powder water suspension was attempted to increase surface hardness. The hardness of the laser-irradiated surfaces increased by 130% to 200%, and the micro-scale plastic deformation behavior changed. The increase in surface hardness was attributed to the formation of hard crystalline phases.
SURFACE & COATINGS TECHNOLOGY
(2023)
Article
Materials Science, Ceramics
Zhanchen Zhu, Tianfeng Zhou, Yupeng He, Qian Yu, Xibin Wang, Tao Yan, Jiwang Yan, Haihui Ruan
Summary: In this study, a novel two-step precision glass molding (PGM) process is proposed for the fabrication of chalcogenide (ChG) glasses with micro-nano structure arrays. A nickel-phosphorus (Ni-P) mold is used to transfer the antireflective micro-nano structure array to silicate glass, which is then used as a mold to replicate the structured surface onto the ChG glass. The results demonstrate high forming accuracy and favorable infrared optical transmission characteristics of the ChG glass micro-nano structure array, while the silicate glass proves to be a suitable mold material for the ChG glass molding process. This work provides a novel PGM technique for ChG glass materials.
CERAMICS INTERNATIONAL
(2023)
Article
Chemistry, Physical
Jing Hong, Haoxiang Wu, Hu Huang, Lin Zhang, Zhiyu Zhang, Minqiang Jiang, Jiwang Yan
Summary: In this study, nanosecond laser nitriding was used to improve the surface hardness and tribological characteristics of metallic glasses. Three laser nitrided surfaces with different hardness were prepared and their tribological characteristics were systematically investigated. The results showed that the hardness of the laser nitrided surfaces increased by 47.94%, 114.56%, and 171.99% compared to the original alloy, and the coefficients of friction were reduced by 29.12%, 65.05%, and 71.84%, respectively. Additionally, the scratch damage mechanisms were analyzed based on the various features of residual scratches and surrounding chips under different conditions.
Article
Materials Science, Multidisciplinary
Yuka Yamamuro, Tomotaka Shimoyama, Jiwang Yan
Summary: Femtosecond pulsed laser irradiation was used to generate numerous nanopores on the surface of yttria-stabilized zirconia (YSZ) without causing thermal damage to the material. The nanopore generation mechanism involved light focusing and ablation inside the YSZ grains. This study demonstrates the feasibility of selectively fabricating nanopores on YSZ surfaces for various applications.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Article
Engineering, Manufacturing
Weihai Huang, Jiwang Yan
Summary: In this study, the tool-workpiece interaction mechanisms in cutting curved microstructures on 4H-SiC (0001) were explored through ultraprecision diamond turning. It was found that microcracks easily occurred in the feed-in/cut-in area of the micro-dimples due to large friction-induced tensile stress. Dimples located on different cleavage directions exhibited varying tendencies to cause surface cracking and had different subsurface damage characteristics.
INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE
(2023)
Article
Materials Science, Multidisciplinary
Chao Wang, Hu Huang, Mingming Cui, Zhiyu Zhang, Lin Zhang, Jiwang Yan
Summary: Superhydrophobicity was achieved on the FeCoCrMnNi surface by synergistic laser texturing and low temperature annealing. Textured surfaces exhibited excellent superhydrophobicity at different hatching intervals and a maximum contact angle of 165 degrees was obtained. The created superhydrophobic surfaces possessed good liquid capture, self-cleaning capabilities, and enabled magnification for optical imaging.
JOURNAL OF LASER APPLICATIONS
(2023)
Article
Engineering, Industrial
Yupeng He, Tianfeng Zhou, A. Senthil Kumar, Xibin Wang, Jiwang Yan
Summary: The shear interference and chip removal interference between different tool edges during non-free cutting are the main reasons for the deformation of micron-submicron grooves. This paper presents a new variable shear angle removal model to understand the material removal mechanism and cutting-induced deformation of micron-submicron grooves in non-free cutting. Finite element simulations and high-speed cutting experiments are conducted to analyze the cutting microstate and dynamic deformation of the micron-submicron grooves.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2023)
Article
Engineering, Multidisciplinary
Shigeru Tanikawa, Yusuke Sato, Jiwang Yan
Summary: With the advancement of optical technologies such as VR and 3D sensing, there is a growing demand for optical components with complex shapes. Ultra-precision diamond turning is a common method used for freeform optics. However, a time delay caused by the independent control system of the fast tool servo (FTS) can lead to angular misalignment and form errors. In this paper, a novel method for measuring and compensating for the time delay was proposed, resulting in improved form accuracy for freeform optics.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2023)
Article
Engineering, Manufacturing
Toshiki Tsuchida, Weihai Huang, Jiwang Yan
Summary: This study investigates the processing characteristics of yttria-stabilized zirconia (YSZ) ceramic under ultrasonic vibration-assisted burnishing (UVB) enhanced by flexible stage and tool rotation techniques. The results show that the use of flexible stage-enhanced UVB reduces the fluctuation of burnishing force and produces a smooth surface with a reduced surface roughness. The use of tool rotation-enhanced UVB forms arc-shaped surface textures and further reduces the surface roughness. Stress-induced phase transformation of YSZ is observed in all burnished surfaces. This study demonstrates the feasibility of manufacturing YSZ with a smooth surface and high residual compressive stress.
PRODUCTION ENGINEERING-RESEARCH AND DEVELOPMENT
(2023)
Article
Engineering, Manufacturing
Mohamed Wagih, Ibrahem Maher, Hassan El-Hofy, Jiwang Yan, Mohsen A. Hassan
Summary: Trochoidal milling is a machining method used to extend cutting tool life. This paper analyzes and experiments the elliptical tool path and proposes a novel linear-elliptical tool path to enhance the performance. The effects on material removal rate, cutting forces, walls waviness, and surface roughness are investigated. The results show improved material removal rate and surface quality, making the linear-elliptical paths promising in increasing the performance of trochoidal milling.
CIRP JOURNAL OF MANUFACTURING SCIENCE AND TECHNOLOGY
(2023)
Article
Engineering, Industrial
Weihai Huang, Kodai Nagayama, Jiwang Yan
Summary: This study investigates the fabrication of spherical and hexagonal microlens arrays on calcium fluoride (CaF2) using diamond turning. The study demonstrates that microcracks tend to be generated during the cutting process, especially when cutting along specific directions. By reducing the maximum undeformed chip thickness and using a depth-offsetting segment cutting method, high-quality microlens arrays without surface cracking can be achieved. This study proves the feasibility of fabricating high-quality freeform microstructured surfaces on CaF2 and other soft-brittle materials through diamond turning.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2023)
