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Towards Sustainable Grinding of Difficult-to-Cut Alloys-A Holistic Review and Trends

Chinese Journal of Mechanical Engineering 2024年第2期37卷 1-28页

作者： Ning Qian Jiajia Chen Aqib Mashood Khan Biao Zhao Yurong Chen Wenfeng Ding yucan fu Jiuhua Xu Jiangsu Key Laboratory of Precision and Micro-Manufacturing Technology Nanjing University of Aeronautics and AstronauticsNanjing 210016China College of Mechanical and Electronic Engineering Nanjing Forestry UniversityNanjing 210037China JITRI Institute of Precision Manufacturing Nanjing 211805China

Grinding,a critical precision machining process for difficult-to-cut alloys,has undergone continual technological advancements to improve machining ***,the sustainability of this process is gaining heightened attention due to significant challenges associated with the substantial specific grinding energy and the extensive heat generated when working with difficult-to-cut alloys,renowned for their exceptional physical and mechanical *** response to these challenges,the widespread application of massive coolant in manufacturing industries to dissipate grinding heat has led to complex post-cleaning and disposal ***,in turn,has resulted in issues such as large energy consumption,a considerable carbon footprint,and concerns related to worker health and safety,which have become the main factors that restrict the development of grinding *** paper provides a holistic review of sustainability in grinding difficult-to-cut alloys,encompassing current trends and future *** examination extends to developing grinding technologies explicitly tailored for these alloys,comprehensively evaluating their sustainability ***,the exploration delves into innovative sustainable technologies,such as heat pipe/oscillating heat pipe grinding wheels,minimum quantity lubrication,cryogenic cooling,and *** groundbreaking technologies aim to reduce dependence on hazardous coolants,minimizing energy and resource consumption and carbon emissions associated with coolant-related or subsequent disposal *** essence of these technologies lies in their potential to revolutionize traditional grinding practices,presenting environmentally friendly ***,future development trends and research directions are put forward to pursue the current limitation of sustainable grinding for difficult-to-cut *** paper can guide future research and development efforts toward more environmentally friendly

关键词： Grinding Sustainability Cooling Energy consumption Carbon footprint Difficult-to-cut alloys

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难加工材料绿色磨削用相变储热复合砂轮的研制

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机械工程学报 2024年第3期60卷 405-414页

作者：赫青山谢永晨崔仲鸣傅玉灿河南工业大学机电工程学院郑州450001 南京航空航天大学机电学院南京210016

高强韧性难加工材料在磨削时容易发生工件表面烧伤,而常规使用磨削液冷却带来的高能耗、环境污染等问题已不容忽视。提出利用沸腾传热和储热技术原理改善砂轮的热学性能实现砂轮对磨削弧区的强化换热,研制了具有高传热系数和较大热容属... 详细信息

高强韧性难加工材料在磨削时容易发生工件表面烧伤,而常规使用磨削液冷却带来的高能耗、环境污染等问题已不容忽视。提出利用沸腾传热和储热技术原理改善砂轮的热学性能实现砂轮对磨削弧区的强化换热,研制了具有高传热系数和较大热容属性的相变储热复合砂轮,并分析了复合砂轮的传热系数和等效热容。设计制作了复合砂轮热学性能分析装置,通过监测多个位置温度变化分析了不同热流密度、工质注入量和散热条件对复合砂轮热学性能的影响,最后进行干磨削高温合金GH4169对比试验。结果表明,复合砂轮的传热系数相对于传统金属基体砂轮可提高2~3倍,工质进入沸腾传热的启动时间在6~15 s,同时增加砂轮热容可以有效减少弧区热量积累以及减缓弧区温升速率;在缓进给深切干磨工艺下使用相变储热复合砂轮的磨削温度在330℃以下,相对于传统砂轮降低了20%。

关键词：磨削超硬磨料砂轮高温合金绿色加工沸腾传热

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基于复合在机测量的双公差约束下负余量曲面的适应性加工

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中国科学：技术科学 2024年第1期54卷 91-106页

作者：丁大伟傅玉灿徐韬锐徐丰羽南京邮电大学自动化学院、人工智能学院南京210023 南京航空航天大学机电学院南京210016

针对复杂舱体进气道曲面热成形铸造毛坯尺寸一致性差、轮廓度和壁厚成形精度低等问题,本文提出基于复合在机测量的双公差约束下负余量曲面适应性加工方法.首先搭建复合在机测量平台,为减少数据迟滞,开发同步数据采集系统,提出激光传感... 详细信息

针对复杂舱体进气道曲面热成形铸造毛坯尺寸一致性差、轮廓度和壁厚成形精度低等问题,本文提出基于复合在机测量的双公差约束下负余量曲面适应性加工方法.首先搭建复合在机测量平台,为减少数据迟滞,开发同步数据采集系统,提出激光传感器位姿迭代标定方法并分析测量误差;随后在曲面轮廓测量数据指导下,通过精确法矢解算实现壁厚的高精度超声在机测量.面向负余量曲面加工,建立轮廓度公差和壁厚公差双重约束下的数学模型,以公差占用度、不均匀度以及一致度为优化目标,在不同权重参数下实现数据驱动的新曲面重建;随后,针对复杂舱体进气道曲面制定了复合在机测量与适应性加工策略,并进行有效性验证.结果表明,轮廓度测量最大正负误差分别为+0.0083和-0.0073 mm,壁厚测量误差均在0.03 mm以内,表明在机测量系统有效.此外,该舱体进气道曲面存在负余量为-0.0524 mm区域,适应性加工后轮廓度最大正偏差和最小负偏差分别为+0.0538和-0.3655 mm,壁厚偏差最大值和最小值分别为+0.16和-0.22 mm,满足公差要求(轮廓度:-0.5~+1 mm,壁厚:-0.4~+0.2 mm)且可实现全曲面高精高效适应性加工.

关键词：复合在机测量公差约束负余量曲面适应性加工

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Ag10CuZnSn-xIn-yCe低银钎料组织及性能

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焊接学报 2024年第6期45卷 113-120页

作者：徐佳琛傅玉灿杨燕李镇何智勇贾允南京工业职业技术大学电气工程学院南京210023 南京航空航天大学机电学院南京210016 宁德时代(上海)智能科技有限公司上海201306

通过向Ag10CuZnSn低银钎料中添加微量的In元素和Ce元素,研究了In元素和Ce元素的复合添加对低银钎料的固相线温度液相线温度和铺展性能的影响,同时分析了两种合金元素对Ag10CuZnSn钎料的显微组织及钎焊接头力学性能的影响规律.结果表明,... 详细信息

通过向Ag10CuZnSn低银钎料中添加微量的In元素和Ce元素,研究了In元素和Ce元素的复合添加对低银钎料的固相线温度液相线温度和铺展性能的影响,同时分析了两种合金元素对Ag10CuZnSn钎料的显微组织及钎焊接头力学性能的影响规律.结果表明,微量In元素和Ce元素的添加可以显著地降低Ag10CuZnSn低银钎料的固相线和液相线温度,同时可以提高Ag10CuZnSn钎料在T2紫铜和304不锈钢基板上的铺展面积,当In元素和Ce元素的质量分数分别为1.5%和0.15%时,钎料在T2紫铜和304不锈钢上的铺展面积分别提升了21.1%和35.7%. In元素和Ce元素可以改善低银钎料的显微组织,当In元素和Ce元素的质量分数分别为1.5%和0.15%时,Ag10CuZnSn低银钎料显微组织的细化作用最为明显,此时304不锈钢钎焊接头的抗剪强度也达到最大值,为375 MPa.然而,质量分数3%的In元素和质量分数0.5%的Ce元素会在Ag10CuZnSn钎料的显微组织中形成脆性的Ag-In-Sn金属间化合物相和Sn-Ce稀土相,钎焊接头的抗剪强度也有所降低.

关键词：低银钎料熔化特性铺展性能显微组织力学性能

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Surface micro-texture on sapphire fabricated by laser ablation trajectory regulation

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Chinese Journal of Aeronautics 2022年第3期35卷 525-536页

作者： Quanli ZHANG Qiwen WANG Zhen ZHANG yucan fu Jiuhua XU College of Mechanical and Electrical Engineering Nanjing University of Aeronautics and AstronauticsNanjing 210016China Jiangsu Key Laboratory of Precision and Micro-Manufacturing Technology Nanjing University of Aeronautics and AstronauticsNanjing 210016China

Fabrication of the surface micro-texture on the C-plane sapphire is undertaken by a355 nm Ultraviolet(UV)pulsed *** surface micro-textures of sapphire with different laser scanning line spacing ranging from 10 lm to 100 lm are obtained,where the selection range of scanning line spacing is controlled in the range of the groove width and plasma width to obtain a surface of high Peak-Valley(PV)value.A reasonable processing order is proposed to manufacture different types of surface micro-textures on sapphire by laser ablation trajectory *** the multiple-passes laser ablation of sapphire by the UV nanosecond pulsed laser,the scanning lines in each direction is treated as once *** this basis,the multiple processing can be carried out to avoid the influence of the subsequent scanning on the machined *** addition,the effect of different scanning line spacing on the PV value is quantified and different types of surface microtextures on sapphire,including the squares,the rhombuses and the hexagons,are successfully fabricated,which can be applied in the friction reduction or anti-reflection field.

关键词： Laser ablation trajectory Sapphire Scanning line spacing Surface micro-texture PV values

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面向高速磨削强化传热的振荡热管测试平台设计研究

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机械设计 2024年第6期41卷 114-122页

作者：张新鹏钱宁姜帆傅玉灿徐九华南京航空航天大学机电学院江苏南京210016

振荡热管砂轮在航空难加工材料的磨削加工中可以显著降低磨削温度,防止磨削烧伤。为了更好地指导振荡热管砂轮设计,需探究振荡热管在不同旋转条件下的传热性能,文中设计了全新的旋转振荡热管传热性能试验平台。通过磁耦合谐振无线供电... 详细信息

振荡热管砂轮在航空难加工材料的磨削加工中可以显著降低磨削温度,防止磨削烧伤。为了更好地指导振荡热管砂轮设计,需探究振荡热管在不同旋转条件下的传热性能,文中设计了全新的旋转振荡热管传热性能试验平台。通过磁耦合谐振无线供电的方式为振荡热管的加热元件供电,实现振荡热管模拟磨削热载荷的加载;通过微控制器采集温度信息,并以无线通信的方式传输温度数据,以克服现有的基于电刷滑环的试验装置在高转速下存在的信号干扰和机械磨损等问题;通过试验确定了无线供电装置的最佳工作参数,测定了信号采集系统的测量误差,并通过旋转振荡热管的传热性能试验验证了测试平台的性能。

关键词：磨削热振荡热管磁耦合谐振无线通信试验平台设计

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Grain erosion wear properties and grinding performance of porous aggregated cubic boron nitride abrasive wheels

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Chinese Journal of Aeronautics 2023年第6期36卷 446-459页

作者： Biao ZHAO Xin WANG Wenfeng DING Yang WANG yucan fu Yanjun ZHAO Jianhui ZHU National Key Laboratory of Science and Technology on Helicopter Transmission Nanjing University of Aeronautics and AstronauticsNanjing 210016China State Key Laboratory of Superabrasives Zhengzhou Research Institute for Abrasive&GrindingZhengzhou 450001China

Cubic boron nitride(cBN)superabrasive grinding wheels exhibit unique advantages in the grinding of difficult-to-cut materials with high strength and toughness,such as titanium alloys and ***,grinding with multilayered metallic cBN superabrasive wheels faces problems in terms of grain wear resistance,the chip storage capability of the working layers and the stability and controllability of the dressing ***,in this work,novel metallic cBN superabrasive wheels with aggregated cBN(AcBN)grains and open pore structures were fabricated to improve machining efficiency and surface *** to the grinding trials,the airborne abrasive blasting process was conducted and the abrasive blasting parameters were optimized in view of wear properties of cBN grains and metallic matrix ***,the comparative experiments were performed and then the variations in grinding force and force ratio,grinding temperature,tool wear morphology and ground surface quality of the multilayered AcBN grinding wheels were investigated during machining Ti-6Al-4V *** consideration of the variations of grain erosion wear volume and material removal rate per unit of pure metallic matrix materials as the abrasive blasting parameters changes,the optimal abrasive blasting parameters were identified as the SiC abrasive mesh size of 60#and the abrasive blasting distance and time of 60 mm and 15 s,*** as-developed AcBN grains exhibited better fracture toughness and impact resistance than monocrystalline cBN(McBN)grains because of the existence of metal-bonded materials amongst multiple cBN particles that decreased crack propagation inside whole *** metallic porous AcBN wheels had lower grinding forces and temperature and better ground surface quality than vitrified McBN wheels due to the constant layer-by-layer exposure of cBN particles in the working layer of AcBN wheels.

关键词： Air-borne abrasive blasting Aggregated cBN abrasive grains Grinding performance Ground surface quality Self-sharpening ability

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An investigation on adaptively machining the leading and tailing edges of an SPF/DB titanium hollow blade using free-form deformation

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Chinese Journal of Aeronautics 2018年第1期31卷 178-186页

作者： Zhengcai ZHAO Jiuhua XU yucan fu Zhiqiang LI College of Mechanical and Electrical Engineering Nanjing University of Aeronautics and Astronautics Nanjing 210016 China Beijing Aeronautics Manufacturing Technology Research Institute Beijing 100024 China

Titanium hollow blades are characterized with lightweight and high structural strength, which are widely used in advanced aircraft engines nowadays. Superplastic forming/diffusion bonding （SPF/DB） combined with numerical control （NC） milling is a major solution for manufacturing titanium hollow blades. Due to the shape deviation caused by multiple heat and pressure cycles in the SPF/DB process, it is hard to manufacture the leading and tailing edges by the milling process. This paper presents a new adaptive machining approach using free-form deformation to solve this problem. The actual SPF/DB shape of a hollow blade was firstly inspected by an on-machine measurement method. The measured point data were matched to the nominal SPF/DB shape with an improved ICP algorithm afterwards, by which the point-pairs between the measurement points and their corresponding points on the nominal SPF/DB shape were established, and the maximum modification amount of the final nominal shape was constrained. Based on the displacements between the point-pairs, an accurate FFD volume was iteratively calculated. By embedding the final nominal shape in the deformation space, a new final shape of the hollow blade was built. Finally, a series of measurement and machining tests was performed, the results of which validated the feasibility of the proposed adaptive machining approach.

关键词： Adaptive machining Blade geometry Free-form deformation Reconstruction Titanium

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Machinability of damage-tolerant titanium alloy in orthogonal turn-milling

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Frontiers of Mechanical Engineering 2020年第3期15卷 504-515页

作者： Tao SUN Lufang QIN Junming HOU yucan fu Jiangsu Key Laboratory of Large Engineering Equipment Detection and Control Xuzhou University of TechnologyXuzhou 221111China Industrial Center Nanjing Institute of TechnologyNanjing 211167China College of Mechanical and Electrical Engineering Nanjing University of Aeronautics and AstronauticsNanjing 210016China

The damage-tolerant titanium alloy TC21 is used extensively in important parts of advanced aircraft because of its high strength and durability. However, cutting TC21 entails problems, such as high cutting temperature, high tool tip stress, rapid tool wear, and difficulty guaranteeing processing quality. Orthogonal turn-milling can be used to solve these problems. In this study, the machinability of TC21 in orthogonal turn-milling is investigated experimentally to optimize the cutting parameters of orthogonal turn-milling and improve the machining efficiency, tool life, and machining quality of TC21. The mechanism of the effect of turn-milling parameters on tool life is discussed, the relationship between each parameter and tool life is analyzed, and the failure process of a TiAlN-coated tool in turn-milling is explored. Experiments are conducted on the integrity of the machined surface (surface roughness, metallographic structure, and work hardening) by turn-milling, and how the parameters influence such integrity is analyzed. Then, reasonable cutting parameters for TC21 in orthogonal turn-milling are recommended. This study provides strong guidance for exploring the machinability of difficult-to-cut-materials in orthogonal turn-milling and improves the applicability of orthogonal turn-milling for such materials.

关键词： orthogonal turn-milling damage-tolerant titanium alloy tool life and failure machined surface integrity machinability

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Tool Wear in Turning of Titanium Alloy after Thermohydrogen Treatment

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Chinese Journal of Mechanical Engineering 2012年第4期25卷 776-780页

作者： WEI Weihua XU Jiuhua fu yucan YANG Shubao College of Mechanical and Electrical Engineering Nanjing University of Aeronautics and Astronautics Nanjing 210016 China

The influence of hydrogen contents on the tool wear has been mainly focused on the flank wear of the common tool,and the influence of hydrogen contents on the rake crater wear（main wear type） of the tool,particularly for the fine granular material tool,has been less investigated *** this paper,for the purpose of researching the influence of hydrogen contents on tool wear,the titanium alloy Ti-6Al-4V is hydrogenated at 800 ℃ by thermohydrogen treatment technology and the turning experiments are carried out by applying uncoated WC-Co cemented carbide *** three-dimensional video microscope is used to take photos and measure tool *** results show that both of crater wear depth（KT） and average flank wear width（VB） firstly decreases and then increases with the increasing of hydrogen *** maximum reducing amplitude of KT and VB is about 50% and 55%,*** the given conditions,the optimum hydrogen content is 0.26%.It is considered that the reduction of cutting temperature is an important factor for improving tool wear after the Ti-6Al-4V alloy is properly ***,the reasons of hydrogen effect on the tool wear are chiefly attributed to comprehensive effect of hydrogen contents on microstructure,physical properties and dynamic mechanical properties of the Ti-6Al-4V *** proposed research provides the basic data for evaluating the machinability of hydrogenation Ti-6Al-4V alloy,and promotes practical application of thermohydrogen treatment technology in titanium alloys.

关键词： titanium alloy hydrogenation cutting temperature crater wear flank wear

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