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Special issue： Ultra-precision machining

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Frontiers of Mechanical Engineering 2017年第1期12卷 1-2页

作者： Zhuangde JIANG Dongming GUO State Key Laboratory for Manufacturing Systems Engineering International Joint Laboratory for Micro/Nano Manufacturing and MeasurementTechnologies Collaborative Innovation Center of Suzhou Nano Science and Technology School of Mechanical Engineering Xi'an JiaotongUniversity Xi'an 710049 China Key Laboratory for precision and Non-traditional machining Technology of Ministry of Education Dalian University of Technology Dalian 116024China

This special issue in Frontiers of Mechanical Engineering contains seventeen papers contributed by prestigious experts from five countries, including one prospect paper, four research papers and twelve review papers. These papers cover a broad area of the ultra-precision machining, and focus on the recent advances on a wide variety of machining methods, such as precision molding, figuring, milling, lapping and diamond machining, to illustrate how various materials in the macro-scale or micro-scale can be machined with high precision, low surface^subsurface damage and ultra-smooth surfaces to meet the demands of numerous application areas, including high-power laser systems, consumer electronics, flexible devices, etc. Some other hot topics, such as the measurement and simulation technology in the ultra-precision machining field, are also covered to provide the readers with a more comprehensive view.

关键词： Special Ultra precision machining

Optimal tool design in micro-milling of difficult-to-machine materials

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Advances in Manufacturing 2023年第2期11卷 222-247页

作者： Lorcan O'Toole Feng-Zhou Fang Centre of Micro/Nano Manufacturing Technology(MNMT-Dublin) University College DublinDublin 4Ireland State Key Laboratory of precision Measuring Technology and Instruments Laboratory of Micro/Nano Manufacturing Technology(MNMT)Tianjin UniversityTianjin300072People's Republic of China

The limitations of significant tool wear and tool breakage of commercially available fluted micro-end mill tools often lead to ineffective and inefficient manufacturing,while surface quality and geometric dimensions remain unacceptably poor.This is especially true for machining of difficult-to-machine(DTM)materials,such as super alloys and ceramics.Such conventional fluted micro-tool designs are generally down scaled from the macro-milling tool designs.However,simply scaling such designs from the macro to micro domain leads to inherent design flaws,such as poor tool rigidity,poor tool strength and weak cutting edges,ultimately ending in tool failure.Therefore,in this article a design process is first established to determine optimal micro-end mill tool designs for machining some typical DTM materials commonly used in manufacturing orthopaedic implants and micro-feature moulds.The design process focuses on achieving robust stiffness and mechanical strength to reduce tool wear,avoid tool chipping and tool breakage in order to efficiently machine very hard materials.Then,static stress and deflection finite element analysis(FEA)is carried out to identify stiffness and rigidity of the tool design in relation to the maximum deformations,as well as the Von Mises stress distribution at the cutting edge of the designed tools.Following analysis and further optimisation of the FEA results,a verified optimum tool design is established for micro-milling DTM materials.An experimental study is then carried out to compare the optimum tool design to commercial tools,in regards to cutting forces,tool wear and surface quality.

关键词： precision machining Micro-milling Difficult-to-machine(DTM) Tool wear Micro-tool design Surface quality

precision micro-milling process:state of the art

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Advances in Manufacturing 2021年第2期9卷 173-205页

作者： Lorcan O’Toole Cheng-Wei Kang Feng-Zhou Fang Center of Micro/Nano Manufacturing Technology(MNMT-Dublin) University College DublinDublin 4Ireland State Key Laboratory of precision Measuring Technology and Instruments Center of Micro/Nano Manufacturing Technology(MNMT)Tianjin UniversityTianjin 300072People’s Republic of China

Micro-milling is a precision manufacturing process with broad applications across the biomedical,electronics,aerospace,and aeronautical industries owing to its versatility,capability,economy,and efficiency in a wide range of materials.In particular,the micro-milling process is highly suitable for very precise and accurate machining of mold prototypes with high aspect ratios in the microdomain,as well as for rapid micro-texturing and micro-patterning,which will have great importance in the near future in bio-implant manufacturing.This is particularly true for machining of typical difficult-to-machine materials commonly found in both the mold and orthopedic implant industries.However,inherent physical process constraints of machining arise as macromilling is scaled down to the microdomain.This leads to some physical phenomena during micromilling such as chip formation,size effect,and process instabilities.These dynamic physical process phenomena are introduced and discussed in detail.It is important to remember that these phenomena have multifactor effects during micro-milling,which must be taken into consideration to maximize the performance of the process.The most recent research on the micro-milling process inputs is discussed in detail from a process output perspective to determine how the process as a whole can be improved.Additionally,newly developed processes that combine conventional micro-milling with other technologies,which have great prospects in reducing the issues related to the physical process phenomena,are also introduced.Finally,the major applications of this versatile precision machining process are discussed with important insights into how the application range may be further broadened.

关键词： precision machining Micro-milling Size effect Deflection Runout Tool wear

Integrated Simulation Method for Interaction between Manufacturing Process and Machine Tool

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Chinese Journal of Mechanical Engineering 2016年第6期29卷 1090-1095页

作者： CHEN Wanqun HUO Dehong XIE Wenkun TENG Xiangyu ZHANG Jiayi School of Mechanical and Systems Engineering Newcastle University Center for precision Engineering Harbin Institute of Technology

The interaction between the machining process and the machine tool （IMPMT） plays an important role on high precision components manufacturing. However, most researches are focused on the machining process or the machine tool separately, and the interaction between them has been always overlooked. In this paper, a novel simplified method is proposed to realize the simulation of IMPMT by combining use the finite element method and state space method. In this method, the transfer function of the machine tool is built as a small state space. The small state space is obtained from the complicated finite element model of the whole machine tool. Furthermore, the control system of the machine tool is integrated with the transfer function of the machine tool to generate the cutting trajectory. Then, the tool tip response under the cutting force is used to predict the machined surface. Finally, a case study is carried out for a fly-cutting machining process, the dynamic response analysis of an ultra-precision fly-cutting machine tool and the machined surface verifies the effectiveness of this method. This research proposes a simplified method to study the IMPMT, the relationships between the machining process and the machine tool are established and the surface generation is obtained.

关键词： dynamic analysis state space surface generation machining interaction precision machining

Smart Cutting Tools and Smart machining: Development Approaches, and Their Implementation and Application Perspectives

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Chinese Journal of Mechanical Engineering 2017年第5期30卷 1162-1176页

作者： Kai Cheng Zhi-Chao Niu Robin C.Wang Richard Rakowski Richard Bateman College of Engineering Design and Physical SciencesBrunel University London

Smart machining has tremendous potential and is becoming one of new generation high value precision manufacturing technologies in line with the advance of Industry 4.0 concepts. This paper presents some innovative design concepts and, in particular, the development of four types of smart cutting tools, including a force-based smart cutting tool, a temperature-based internally-cooled cutting tool, a fast tool servo （FTS） and smart collets for ultra- precision and micro manufacturing purposes. Implemen- tation and application perspectives of these smart cutting tools are explored and discussed particularly for smart machining against a number of industrial application requirements. They are contamination-free machining, machining of tool-wear-prone Si-based infra-red devices and medical applications, high speed micro milling and micro drilling, etc. Furthermore, implementation tech- niques are presented focusing on：（a） plug-and-produce design principle and the associated smart control algo- rithms, （b） piezoelectric film and surface acoustic wave transducers to measure cutting forces in process, （c） critical cutting temperature control in real-time machining, （d） in- process calibration through machining trials, （e） FE-based design and analysis of smart cutting tools, and （f） applica- tion exemplars on adaptive smart machining.

关键词： Smart cutting tool Smart machining Fast toolservo （FFS） precision machining Micro manufacturing Smart tooling

Design and Characterization of a Low-Cost Piezoelectric Vibration Energy Harvester with Bulk PZT Film

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Instrumentation 2018年第4期5卷 30-38页

作者： TIAN Xingyao HE Xuefeng Key Laboratory of Optoelectronic Technology and Systems of the Education Ministry of China Chongqing University

To improve the efficiency of MEMS piezoelectric vibration energy harvesters(PVEHs), the bulk lead zirconate titanate(PZT) has been used to substitute the thin film PZT for the higher mechanical-electrical coupling coefficients. The expensive equipment of micromachining set a high entry barrier on the research of PVEHs with high efficiency. To solve this issue, this paper developed an efficient PVEH with bulk PZT using common precision machining, whose dimensions and electrical outputs are comparable to the MEMS devices. After numerically analyzing the effects of the length ratio of the proof mass to the harvester on the output power, a compact PVEH consisting of a cantilevered uni-morph and a tungsten proof mass was designed. Simulations show that the mechanical damping ratio and the thickness have little effects on the optimized length ratio. By using a uni-morph with the copper structural layer of about 80-90μm and the bulk PZT-5 H layer of 139μm, a low-cost harvester prototype was assembled. The key parameters of the prototype were experimentally identified and compared with the theoretical predictions. Under the harmonic base excitation of 0.4 g(where g = 9.8 m/s^2) at 160 Hz, the maximum output power of the prototype is about 76.7μW, with the normalized power density of about 3.35 mW/cm^3/g^2. Under base excitation of 0.4 g at 159 Hz, the prototype charged a 680μF capacitor from 0 to 4.84 V in about 154 seconds.

关键词： Energy Harvesting Vibration Piezoelectricity Bulk Lead Zirconate Titanate precision machining

Survey for Real-time Error Prediction and Compensation Technology for Thread Grinder

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Survey for Real-time Error Prediction and Compensation Techn...