Article
Materials Science, Multidisciplinary
Afifah Z. Juri, Yanzhong Zhang, Andrei Kotousov, Ling Yin
Summary: This study investigates the response of zirconia materials to edge chipping damage induced in conventional and ultrasonic vibration-assisted diamond machining. The results show that the scale of edge chipping damage is influenced by vibration amplitude, and ultrasonic machining can significantly reduce damage caused by brittle fracture.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2021)
Article
Acoustics
Yunze Li, Dongzhe Zhang, Hui Wang, Gaihua Ye, Rui He, Weilong Cong
Summary: Brittle materials are widely used in various industries, and there is a growing demand for high-precision micro-machining of these materials. Traditional ultra-precision micro-machining can lead to issues such as workpiece cracking and low surface quality. Rotary ultrasonic machining is a nontraditional process that can effectively address these problems. This study investigates the effects of ultrasonic vibration and input parameters on cutting force and surface quality in micro-machining of brittle materials.
ULTRASONICS SONOCHEMISTRY
(2022)
Article
Materials Science, Ceramics
Islam Zakiev, Michael Storchak, George A. Gogotsi, Vadim Zakiev, Yuliia Kokoieva
Summary: The edge toughness of brittle materials is currently determined by the value of edge toughness, and an instrumented micro-edge chipping (IMEC) test has been proposed and tested to provide a closer correlation between edge toughness values. Comparison between macro-EF and IMEC tests for various materials showed almost identical trends in the ratio of edge toughness values, while the duration of the chip process varied among the studied materials.
CERAMICS INTERNATIONAL
(2021)
Article
Chemistry, Analytical
Shanhua Zhang, Manfeng Gong, Haishan Lian, Jianfeng Wu, Weijie Zhu, Zhengwei Ou
Summary: This paper proposes high-speed rotary ultrasonic machining (HRUM) technology to solve the problems of low machining accuracy and serious tool wear in traditional diamond grinding machining (DGM) microstructure of hard and brittle materials. A HRUM machine tool is developed, with hardware including spindle module, micro-motion system module, ultrasonic machining tank module, and data acquisition (DAQ) system module. Comparative experiments of HRUM and DGM are conducted on small holes in Al2O3 ceramics, showing that HRUM effectively reduces axial cutting forces, reduces binder adhesion, and suppresses slippage while improving tool-cutting ability and extending tool life.
Article
Dentistry, Oral Surgery & Medicine
Afifah Z. Juri, Renan Belli, Ulrich Lohbauer, Heike Ebendorff-Heidepriem, Ling Yin
Summary: This study investigated the edge chipping damage induced by diamond machining of pre-crystallized and crystallized lithium silicate glass-ceramics, and compared it with conventional machining. The results showed that ultrasonic vibration-assisted machining can significantly reduce the edge chipping damage in pre-crystallized LS materials at optimized amplitudes.
Article
Chemistry, Analytical
Marcel Kuruc, Tomas Vopat, Jana Moravcikova, Jan Milde
Summary: This paper focuses on investigating the possibilities of rotary ultrasonic machining (RUM) for preparing asymmetric cutting edge microgeometries of cubic boron nitride (CBN) cutting tools. The experiments show that RUM can be used to process CBN and prepare cutting edge microgeometries of various shapes.
Article
Materials Science, Ceramics
Guochao Qiao, Shicheng Yi, Wei Zheng, Ming Zhou
Summary: Experimental results comparing ultrasonic vibration-assisted scratching and conventional scratching show that ultrasonic vibration can increase the critical load of the brittle-ductile transition, promote crack propagation, and increase the critical scratch interval distance of the crack-inhibiting effect.
CERAMICS INTERNATIONAL
(2022)
Article
Engineering, Mechanical
Tian Lan, Pingfa Feng, Jianfu Zhang, Huilin Zhou, Jianjian Wang
Summary: Rotary ultrasonic machining (RUM) is an effective method for processing difficult-to-cut materials, but the understanding of critical cutting force in RUM system with frequency-tracking module is lacking. This study models the dependency of ultrasonic amplitude on cutting force and develops experimental methods to measure the actual ultrasonic amplitude and critical cutting force. The experimental results validate the models and analyze the influence of electrical and mechanical design on critical cutting force in frequency-tracked RUM system.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2023)
Article
Automation & Control Systems
Yi-Jia Sun, Zhen Chen, Sheng-Jun Ao, Hu Gong, Shu-Yu Gui
Summary: This study investigates the electrical characteristics of the ultrasonic vibration unit in a rotary ultrasonic machining (RUM) system. The relationship between electrical parameters and the resonant frequency of the ultrasonic vibration unit is studied when different tools are clamped. Rotary ultrasonic drilling experiments are conducted to study the effect of processing parameters on the electrical characteristics of the ultrasonic vibration unit. It is found that the variations of electrical parameters are significant under different ultrasonic voltages but not under different feed rates.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Automation & Control Systems
Dongxi Lv, Dong Liu, Mingda Chen, Gang Chen, Chun Yan, Imran Ali, Yingdan Zhu
Summary: By establishing a prediction model and developing relevant correlations, this study proposed a method to reduce or eliminate exit-chipping in the rotary ultrasonic drilling process, ultimately confirming the consistency through experimental validation.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Engineering, Mechanical
Yi-Jia Sun, Hu Gong, Sheng-Jun Ao, Yi Wang, Song-Mei Yuan, Ming-Jie Ding, Tong Guo
Summary: To adapt to diverse cutting tools, a rotary ultrasonic machining (RUM) system is designed to work in a local resonant state. In order to determine the working frequency of cutting tools in RUM, an in-situ characterization method for tool ultrasonic vibration based on radiated acoustic pressure is proposed. Through analytical analysis, numerical simulation, and experimental measurement, the characteristics of acoustic pressure distributions radiated from typical cutting tools in RUM are comprehensively studied. Based on the relationship between acoustic pressure and tool vibration, a measurement strategy and in-situ measurement system are developed, which effectively determine the working frequency and quantify the vibration amplitude of cutting tools in RUM.
MECHANICAL SYSTEMS AND SIGNAL PROCESSING
(2023)
Article
Computer Science, Information Systems
Heng Zhao, Shuyuan Ye, Jianzhong Ju, Zhili Long, Yuhui Yang
Summary: This paper developed a novel heat shrinkable RUM ultrasonic transducer with a working frequency of 60 kHz using an equivalent circuit and finite element method. Three flange mounting structures were proposed to optimize energy transmission at the working resonant frequency. The experimental results showed good consistency with the theoretical calculations, demonstrating the effectiveness of the proposed design.
Article
Automation & Control Systems
Wenbo Bie, Fan Chen, Bo Zhao, Shuangxi Xie
Summary: Longitudinal-torsional coupled vibration rotary ultrasonic machining (LTC-RUM) is effective for surface grinding difficult-to-machine and brittle materials. This study proposed a cutting force model for LTC-RUM end surface grinding of zirconia ceramics, considering the ductile and brittle stages of material removal. Detailed analysis of abrasive particle movement, cutting depth, and material removal rate was conducted, and the evolution of cutting force was predicted. Experimental results validated the feasibility of the developed model, showing good agreement with the predicted results under various input variables. The cutting force was reduced with increased spindle speed and ultrasonic power, and increased with feed rate and cutting depth.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Crystallography
Jingyuan He, Honghua Su, Ning Qian, Pengfei Xu
Summary: SiCf/SiC composite material has excellent properties including high strength, low specific gravity, and high temperature resistance, making it highly promising in the combustion chamber of rockets or aero engines. This study introduces a novel strategy for hole-making in SiCf/SiC parts, namely rotary ultrasonic-assisted drilling (RUAD) using an orderly arranged brazed diamond core drill. The results demonstrate that the proposed approach improves tool life and accuracy in hole-making, enhances drilling quality and efficiency, and reduces drilling force and torque.
Article
Materials Science, Ceramics
Fan Chen, Wenbo Bie, Xiaobo Wang, Bo Zhao
Summary: This study utilized the longitudinal-torsional coupled rotary ultrasonic machining technique to process ZrO2 ceramics and conducted experiments to investigate its effects. The results showed that this machining method significantly reduced cutting force and surface roughness, improved hole surface quality, and reduced abrasive particle wear.
CERAMICS INTERNATIONAL
(2022)
Article
Acoustics
Jianfu Zhang, Ke Ma, Jianjian Wang, Pingfa Feng, Shahzad Ahmad
Summary: This study proposes a method that combines multiple parameters to accurately track the resonance frequency of an ultrasonic system, and verifies the feasibility of this method through theoretical analysis and experiments. The results show that this method can improve tracking accuracy and response rate, and effectively reduce cutting-induced defects in ultrasonic cutting.
IEEE TRANSACTIONS ON ULTRASONICS FERROELECTRICS AND FREQUENCY CONTROL
(2022)
Article
Computer Science, Artificial Intelligence
Wentao Luo, Pingfa Feng, Jianfu Zhang, Dingwen Yu, Zhijun Wu
Summary: A proposed Improved Deep Convolution Generative Adversarial Transfer Learning Model (IDCGAN-TM) integrates generative learning, feature learning, and transfer learning modules to effectively address the limited data problem in assembly equipment and achieve excellent performance in assembly quality diagnosis.
JOURNAL OF INTELLIGENT & FUZZY SYSTEMS
(2022)
Article
Mechanics
Ke Ma, JianJian Wang, Jianfu Zhang, Pingfa Feng, Dingwen Yu, Shahzad Ahmad
Summary: In this study, a force-insensitive impedance compensation (FIC) method was proposed to improve the vibration stability of GMUS for honeycomb machining. Experimental results demonstrated that the compensated ultrasonic cutting system showed an enhanced vibration stability during the machining of Nomex honeycomb composite, with reduced cell collapses.
COMPOSITE STRUCTURES
(2022)
Article
Mathematics, Interdisciplinary Applications
Zhiwei Li, Jianjian Wang, Meng Yuan, Zhongyu Wang, Pingfa Feng, Feng Feng
Summary: In this study, the researchers demonstrate the scaling characteristics of root-mean-squared roughness using the roughness scaling extraction (RSE) method. They propose an universal indicator, H-RSE, to quantify the complexity of both fractal and non-fractal features. The findings show that the RSE method has higher accuracy in quantifying the complexity of fractal features compared to traditional fractal methods, and it can effectively quantify the complexity of non-fractal features as well.
CHAOS SOLITONS & FRACTALS
(2022)
Article
Automation & Control Systems
Jinchuan Yang, Pingfa Feng, Jianfu Zhang, Jianjian Wang
Summary: A novel full wedge-type insert mounting method was developed and its performance was evaluated through simulation and experiments. The results showed that the full wedge-type threaded connection method had less intense vibration amplitude fluctuations compared to the ordinary threaded connection method during insert mounting, which can be attributed to the contact force amplification effects on the wedge-type interface.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Engineering, Mechanical
Zhongpeng Zheng, Jianfu Zhang, Pingfa Feng, Jianjian Wang
Summary: Rotary ultrasonic milling is a new and efficient fabrication method for surface microstructures. However, conventional rotary ultrasonic milling suffers from the interference of secondary back-cutting, resulting in poor controllability of the surface geometries. In this study, oblique rotary ultrasonic milling (ORUM) is proposed to improve the process controllability by eliminating secondary back-cut interference. The efficacy of ORUM is verified through experimental results and its potential for industrial applications is demonstrated by fabricating fish-scale microstructures on freeform surfaces.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2023)
Article
Engineering, Manufacturing
Zhimeng Chen, Pingfa Feng, Jianjian Wang, Feng Feng, Huiting Zha
Summary: This study demonstrates that the cutting performance of Bulk Metallic Glasses can be enhanced only within a carefully-determined window of ultrasonic amplitude. An excessive ultrasonic amplitude may violate the cutting performance.
CIRP JOURNAL OF MANUFACTURING SCIENCE AND TECHNOLOGY
(2022)
Article
Engineering, Manufacturing
Guanxiong Miao, Mohammadamin Moghadasi, Ming Li, Zhijian Pei, Chao Ma
Summary: Shell printing is an advantageous technique that prints a thin shell of the object to enclose loose powder. This study investigated the powder packing in the shell and core for the first time. The density and microstructure of the printed samples showed differences in powder packing between the shell and core, influenced by powder particle size and layer thickness. By selecting the proper layer thickness and powder particle size, shell printing could be a promising method to tailor density and reduce anisotropy.
JOURNAL OF MANUFACTURING AND MATERIALS PROCESSING
(2023)
Article
Materials Science, Ceramics
Quinton Porter, Mohammadamin Moghadasi, Zhijian Pei, Chao Ma
Summary: The objective of this study was to evaluate the feasibility of producing metal-free fully ceramic composites using binder jetting of alumina preforms and spontaneous infiltration by copper in air. Different particle sizes of alumina powders were used as feedstock for binder jetting, followed by standard post-processing steps. The sintered specimens were then infiltrated with copper, resulting in improved mechanical properties compared to the porous sintered specimens. The compressive strength of 826.0 MPa and flexural strength of 317.5 MPa achieved in this study exceed those reported in the literature for binder jetting and/or infiltration of alumina-based specimens.
CERAMICS INTERNATIONAL
(2023)
Article
Engineering, Mechanical
Tian Lan, Pingfa Feng, Jianfu Zhang, Huilin Zhou, Jianjian Wang
Summary: Rotary ultrasonic machining (RUM) is an effective method for processing difficult-to-cut materials, but the understanding of critical cutting force in RUM system with frequency-tracking module is lacking. This study models the dependency of ultrasonic amplitude on cutting force and develops experimental methods to measure the actual ultrasonic amplitude and critical cutting force. The experimental results validate the models and analyze the influence of electrical and mechanical design on critical cutting force in frequency-tracked RUM system.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2023)
Article
Computer Science, Artificial Intelligence
Ganlin Zhao, Pingfa Feng, Jianfu Zhang, Chang Yu, Jianjian Wang
Summary: This paper proposes a novel approach to detect and annotate assembly elements using AR mobile devices in an offline environment. The approach utilizes an improved deep learning object detection network and a spatial 3D annotation algorithm to achieve lightweight and accurate detection. Experimental results show that the proposed approach can assist operators in detecting key assembly elements with reasonable accuracy and significant advantages in operation speed.
EXPERT SYSTEMS WITH APPLICATIONS
(2023)
Article
Engineering, Industrial
Zhimeng Chen, Pingfa Feng, Jianfu Zhang, Feng Feng, Huawen Zhang, Jinhui Yu, Jianjian Wang
Summary: This study proposes a novel ruling process called shaped vibration cutting (SVC) for fabricating relief gratings on difficult-to-cut materials. It utilizes a controllable special-shaped vibration locus of a diamond cutting tool to achieve flexible control of the grating profile. Slope grooving tests were conducted to explore the surface generation and defect formation mechanism, and a defect-less process window was identified. The SVC process successfully fabricated relief gratings on aluminum and silicon, outperforming existing cutting-based texturing techniques.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2023)
Article
Engineering, Multidisciplinary
Huawen Zhang, Pingfa Feng, Feng Feng, Jianfu Zhang, Chunjin Wang, Jianjian Wang
Summary: This study utilizes nanoindentation technique to fabricate 2D nanostructures on metallic surfaces, and successfully produces pyramid-type nanostructures. Based on the unique diffraction characteristic of these 2D nanostructures, a high-decoupling optical variable device is fabricated. Furthermore, a structural color-based bidirectional strain sensor is developed by transferring the 2D nanostructures onto a flexible polymer, and its potential application in wireless measurement of mechanical deformation is verified.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2023)
Article
Chemistry, Multidisciplinary
Peiyuan Ding, Jianfu Zhang, Pingfa Feng, Xiangyu Zhang, Zhongpeng Zheng, Jianjian Wang
Summary: Optical Fourier surfaces are patterned optical surfaces that contain precise sums of sinusoidal waves with well-defined spatial frequencies and amplitudes. They can manipulate diffracted light through Fourier transforms, providing a mathematical method for designing complex diffractive optics. However, current fabrication techniques have low efficiency, limiting their industrial application. This study presents a high-efficiency fabrication approach called multi-frequency vibration cutting (MFVC) and demonstrates the fabrication of specific optical Fourier surfaces on metallic surfaces.
Review
Biotechnology & Applied Microbiology
Al Mazedur Rahman, Taieba Tuba Rahman, Zhijian Pei, Chukwuzubelu Okenwa Ufodike, Jaesung Lee, Alaa Elwany
Summary: This review study analyzes the development of novel materials from agriculturally derived biowastes for additive manufacturing. The study reviews 57 selected publications since 2016, covering various biowastes, additive manufacturing methods, and potential large-scale applications. The findings suggest the need for further research and development to optimize the use of biowastes in additive manufacturing, including material innovation, improving print quality and mechanical properties, and exploring industrial applications.
BIOENGINEERING-BASEL
(2023)
