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Frontiers of Mechanical Engineering 2020年第1期15卷 81-88页

作者： tianfeng zhou Ying WANG Benshuai RUAN Zhiqiang LIANG Xibin WANG Key Laboratory of Fundamental Science for Advanced Machining Beijing Institute of TechnologyBeijing 100081China School of Mechanical Engineering Beijing Institute of TechnologyBeijing 100081China

Friction modeling between the tool and the workpiece plays an important role in predicting the minimum cutting thickness during TC4 micro machining and finite element method(FEM)cutting *** this study,a new three-region friction modeling is proposed to illustrate the material flow mechanism around the friction zone in micro cutting;estimate the stress distributions on the rake,edge,and clearance faces of the tool;and predict the stagnation point location and the minimum cutting *** friction modeling is established by determining the distribution of normal and shear ***,it is applied to calculate the stagnation point location on the edge face and predict the minimum cutting *** stagnation point and the minimum cutting thickness are also observed and illustrated in the FEM *** cutting experiments are conducted to validate the accuracy of the friction and the minimum cutting thickness *** results show that the proposed friction model illustrates the relationship between the normal and sheer stress on the tool surface,thereby validating the modeling method of the minimum cutting thickness in micro cutting.

关键词： tool friction minimum cutting thickness finite element method tool edge radius micro cutting

Precision Milling of Integrated Turbine Based on a Non-Contact On-Machine Measurement System

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Nanomanufacturing and Metrology 2022年第4期5卷 394-402页

作者： Ying Wang tianfeng zhou Jia zhou Min Li Zhiqiang Liang Xibin Wang School of Mechanical Engineering Beijing Institute of TechnologyBeijing100081China Beijing Institute of Technology Chongqing Innovation Center Chongqing401120China Department of Manufacturing Technologies Leibniz Institute for Materials Engineering IWT28359BremenGermany

The machining accuracy of the curved surfaces of integrated turbine blades directly determines the performance and service life of the turbojet engine *** this paper,a non-contact on-machine measurement system is developed for precision milling of integrated turbines to reduce the impact of workpiece deformation,overcutting,tool chatter,and material work *** with the on-machine measurement system obtained high-quality integrated turbine *** geometric accuracy error(PV)is below 3μm,and the surface roughness(Ra)is less than 2μ*** processed integrated turbine blade can achieve the accuracy requirements in the design and manufacturing and can be practically applied to the entire turbojet engine.

关键词： Integrated turbine Precision milling K418 superalloy On-machine measurement Topography compensation

Recent advancements in optical microstructure fabrication through glass molding process

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Frontiers of Mechanical Engineering 2017年第1期12卷 46-65页

作者： tianfeng zhou Xiaohua LIU Zhiqiang LIANG Yang LIU Jiaqing XIE Xibin WANG Key Laboratory of Fundamental Science for Advanced Machining Beijing Institute of Technology Beijing 100081 China School of Mechanical Engineering Beijing Institute of TechnologyBeijing 100081 China

Optical microstructures are increasingly applied in several fields, such as optical systems, precision measurement, and microfluid chips. Microstructures include microgrooves, microprisms, and microlenses. This paper presents an overview of optical microstructure fabrication through glass molding and highlights the applications of optical microstructures in mold fabrication and glass molding. The glass-mold interface friction and adhesion are also discussed. Moreover, the latest advance- ments in glass molding technologies are detailed, including new mold materials and their fabrication methods, viscoelastic constitutive modeling of glass, and micro- structure molding process, as well as ultrasonic vibration- assisted molding technology.

关键词： optical microstructure microgroove micro-lens glass molding process single-point diamond cutting

Alignment error modeling and control of a double-sided microlens array during precision glass molding

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Microsystems & Nanoengineering 2024年第2期10卷 311-322页

作者： Zihao Zeng tianfeng zhou Qian Yu Jia zhou Gang Wang Qiuchen Xie Zifan Wang Xiaoqiang Yao Yubing Guo School of Medical Technology Beijing Institute of TechnologyNo.5 Zhongguancun South StreetHaidian DistrictBeijing100081China School of Mechanical Engineering Beijing Institute of TechnologyNo.5 Zhongguancun South StreetHaidian DistrictBeijing100081China

Double-sided microlens arrays(DSMLAs)include combinations of two single-sided MLAs to overcome positioning errors and greatly improve light transmissivity compared to other types of *** glass molding(PGM)is used to fabricate DSMLAs,but controlling alignment errors during this process is *** this paper,a mold assembly was manufactured with a novel combination of materials to improve the alignment accuracy of mold cores during PGM by using the nonlinear thermal expansion characteristics of the various materials to improve the DSMLA alignment *** establishing a mathematical model of the DSMLA alignment error and a thermal expansion model of the mold-sleeve pair,the relationship between the maximum alignment error of the DSMLA and the mold-sleeve gap was *** research provides a method to optimize the mold-sleeve gap and minimize the alignment error of the *** measured DSMLA alignment error was 10.56μm,which is similar to the predicted maximum alignment *** measurements showed that the uniformity of the homogenized beam spot was 97.81%,and the effective homogeneous area accounted for 91.66%of the total *** proposed method provides a novel strategy to improve the performance of DSMLAs.

关键词： sided alignment error

Mesoscale fabrication of a complex surface for integral impeller blades

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Frontiers of Mechanical Engineering 2017年第1期12卷 116-131页

作者： Xibin WANG tianfeng zhou Lijing XIE Li JIAO Zhibing LIU Zhiqiang LIANG Pei YAN Key Laboratory of Fundamental Science for Advanced Machining Beijing Institute of Technology Beijing 100081 China

Integral impeller is the most important compo- nent of a mini-engine. However, the machining of a mesoscale impeller with a complex integral surface is difficult because of its compact size and high accuracy requirement. A mesoscale component is usually manufac- tured by milling. However, a conventional milling tool cannot meet the machining requirements because of its size and stiffness. For the fabrication of a complex integral impeller, a micro-ball-end mill is designed in accordance with the non-instantaneous-pole envelope principle and manufactured by grinding based on the profile model of the helical groove and the mathematical model of the cutting edge curve. Subsequently, fractal theory is applied to characterize the surface quality of the integral impeller. The fractal theory-based characterization shows that the completed mesoscale integral impeller exhibits a favorable performance in terms of mechanical properties and morphological accuracy.

关键词： mesoscale fabrication micro-milling tool,mesoscale milling impeller blade

Compressional Deformation in Indentation Process for Microlens Array Mold

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Journal of Beijing Institute of Technology 2018年第1期27卷 15-21页

作者： Yaqun Bai Xibin Wang tianfeng zhou Zhiqiang Liang Guang Li School of Mechanical Engineering Beijing Institute of Technology

The structure of a microlens array（ MLA） can be formed on copper by an indentation process which is a new manufacture approach we applied here instead of a traditional method to test the material property,thereby work time can be saved. Single-indentation and multi-indentation are both conducted to generate a single dimple and dimples array,namely micro lens and MLA. Based on finite element simulation method,factors affecting the form accuracy,such as springback at the compressed area of one single dimple and compressional deformation at the adjacent area of dimples arrays,are determined,and the results are verified by experiments under the same conditions. Meanwhile,indenter compensation method is proposed to improve form accuracy of single dimple,and the relationship between pitch and compressional deformation is investigated by modelling seven sets of multi-indentations at different pitches to identify the critical pitch for the MLA＇s indentation processing. Loads and cross-sectional profiles are measured and analyzed to reveal the compressional deformation mechanism. Finally,it is found that MLA at pitches higher than 1. 47 times of its diameter can be manufactured precisely by indentation using a compensated indenter.

关键词： microlens array(MLA) indentation process compensation method compressional deformation

Algorithm of Micro-Grooving and Imaging Processing for the Generation of High-Resolution Structural Color Images

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Nanomanufacturing and Metrology 2020年第3期3卷 187-198页

作者： tianfeng zhou Yupeng He Tianxing Wang Xiaobin Dong Peng Liu Wenxiang Zhao Yao Hu Jiwang Yan Key Laboratory of Fundamental Science for Advanced Machining.Beijing Institute of Technology Beijing 100081China Beijing Key Laboratory for Precision Optoelectronic Measurement Instrument and Technology Beijing Institute of TechnologyBeijing 100081China Department of Mechanical Engineering Faculty of Science and TechnologyKeio UniversityYokohama 223-8522Japan

The use of submicron structures for structural coloration of surfaces has broad applications for color filters,projection displays,virtual reality,and ***,structural color images lack high resolution due to low manufacturing *** this study,the axial-feed fly cutting(AFC)method is proposed to fabricate submicron grooves for the diffraction of visible light to create structural color *** establish the relationship between the color information in the pixels of the original image and the parameters of the array units corresponding to the *** algorithm to determine groove spacing and the tool path is established,and array units with the desired groove spacing are machined to reproduce the structural color *** submicron grooves fabricated by AFC have high quality and good *** to the excellent diffraction performance of the machined grooves,images with high saturation and resolution can be *** is verified that images with various colors can be efficiently fabricated using the proposed method and algorithm.

关键词： Subniicron structure Microgroove Structural coloration Structural-color image Fly cutting Micromachining

Surface modification and functionalization by electrical discharge coating:a comprehensive review

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International Journal of Extreme Manufacturing 2020年第1期2卷 68-99页

作者： Pay Jun Liew Ching Yee Yap Jingsi Wang tianfeng zhou Jiwang Yan Fakulti Kejuruteraan Pembuatan Universiti Teknikal Malaysia MelakaHang Tuah Jaya76100Durian TunggalMelakaMalaysia Marine Engineering College Dalian Maritime University1 Linghai RoadGanjingzi DistrictDalian 116026People’s Republic of China Key Laboratory of Fundamental Science for Advanced Machining Beijing Institute of TechnologyNo.5 Zhongguancun South StreetHaidian DistrictBeijing 100081People’s Republic of China Department of Mechanical Engineering Faculty of Science and TechnologyKeio UniversityHiyoshi 3-14-1Kohoku-kuYokohama 223-8522Japan

Hard coatings are extensively required in industry for protecting mechanical/structural parts that withstand extremely high temperature,stress,chemical corrosion,and other hostile *** discharge coating(EDC)is an emerging surface modification technology to produce such hard coatings by using electrical discharges to coat a layer of material on workpiece surface to modify and enhance the surface characteristics or create new surface *** paper presents a comprehensive overview of EDC technologies for various materials,and summarises the types and key parameters of EDC processes as well as the characteristics of resulting *** provides a systematic summary of the fundamentals and key features of the EDC processes,as well as its applications and future trends.

关键词： electrical discharge coating(EDC) surface modification material characteristics mechanical properties extreme conditions

A review of the techniques for the mold manufacturing of micro/nanostructures for precision glass molding

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International Journal of Extreme Manufacturing 2021年第4期3卷 23-54页

作者： tianfeng zhou Yupeng He Tianxing Wang Zhanchen Zhu Ruzhen Xu Qian Yu Bin Zhao Wenxiang Zhao Peng Liu Xibin Wang School of Mechanical Engineering Beijing Institute of TechnologyBeijing 100081People’s Republic of China Beijing Institute of Technology Chongqing Innovation Center Chongqing 401120People’s Republic of China

Micro/nanostructured components play an important role in micro-optics and optical engineering,tribology and surface engineering,and biological and biomedical engineering,among other *** glass molding technology is the most efficient method of manufacturing micro/nanostructured glass components,the premise of which is meld manufacturing with complementary micro/*** mold manufacturing methods have been developed to fabricate extremely small and high-quality micro/nanostructures to satisfy the demands of functional micro/nanostructured glass components for various ***,the service performance of the mold should also be carefully *** paper reviews a variety of technologies for manufacturing micro/nanostructured *** authors begin with an introduction of the extreme requirements of mold *** following section provides a detailed survey of the existing micro/nanostructured mold manufacturing techniques and their corresponding mold materials,including nonmechanical and mechanical *** paper concludes with a detailed discussion of the authors recent research on nickel-phosphorus(Ni-P)mold manufacturing and its service performance.

关键词： precision glass molding mold manufacturing micro/nanostructure mold material extreme features

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光刻胶掩膜材料超光滑表面切削

光学精密工程 2023年第13期31卷 1909-1921页

作者：李秋怡周天丰周佳胡君剑赵斌北京理工大学机械与车辆学院北京100081 北京理工大学重庆创新中心重庆401120 江西联创电子有限公司江西南昌330000

鉴于以光刻胶为代表的高分子材料的切削特性决定了掩膜微细结构的加工质量,以SU8为研究对象,结合实验和仿真分析研究了光刻胶掩膜的切削特性。通过纳米压痕法测试了光刻胶SU8的应力-应变关系,建立了基于能量法的SU8切削仿真模型,然后采... 详细信息

鉴于以光刻胶为代表的高分子材料的切削特性决定了掩膜微细结构的加工质量,以SU8为研究对象,结合实验和仿真分析研究了光刻胶掩膜的切削特性。通过纳米压痕法测试了光刻胶SU8的应力-应变关系,建立了基于能量法的SU8切削仿真模型,然后采用AdvantEdge FEM模拟了不同切削参数下光刻胶SU8的切削过程,最后开展了光刻胶SU8的超精密加工实验。结合仿真与实验结果,分析了切削参数和刀具前角对表面质量的影响规律,优化了光刻胶SU8的切削加工参数。结果表明:表面粗糙度随着切削速度的增大呈现减小的趋势,随着进给速度和切削深度的增加呈现增大的趋势;当切削速度为2.09 m/s、进给速度为1 mm/min、切削深度为2μm、刀具前角为0°时,光刻胶掩膜的表面粗糙度Ra达到最优为7.4 nm,无微裂纹等微观缺陷。基于切削仿真与实验结果对加工参数进行优化,并在光刻胶SU8掩膜上实现了高精度微透镜阵列结构的加工。

关键词：超精密切削掩膜加工切削仿真光刻胶SU8 微透镜阵列