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Enhanced high-temperature mechanical properties of laser-arc hybrid additive manufacturing of Al-Zn-Mg-Cu alloy via microstructure control

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Journal of Materials Science & Technology 2024年第2期169卷 220-234页

作者： Dehua Liu Dongjiang Wu Yunsong Wang Zhuo Chen Changrong Ge Qingyu Zhao Fangyong Niu Guangyi Ma State Key laboratory of High-performance precision manufacturing Dalian University of TechnologyDalian 116024China

Recently,rapid and cost-effective additive manufacturing solutions for lightweight aluminum alloys with excellent high-temperature mechanical properties have been increasingly in *** this study,we combined laser-arc hybrid additive manufacturing with solution and artificial aging treatments to achieve Al-Zn-Mg-Cu alloy with favorable high-temperature strength via microstructure *** pores became the major defect in the as-deposited and heat-treated *** continuous distribution of eutectics with hard-brittle characteristics at the grain boundaries was destructed following heat ***-densityηprecipitates were uniformly dispersed in the heat-treated Al-Zn-Mg-Cu alloy,whereas appeared coarsened and dissolved at 473 K,owing to the rapid diffusion of Zn and *** average 0.2%yield strength(318±16 MPa)and ultimate tensile strength(362±20 MPa)at 473 K af-ter heat treatment were enhanced by approximately 58%and 51%,respectively,compared to those of the as-deposited *** addition,theηprecipitates contributed to lattice distortions and strain fields,which prevented dislocation motion and increased slip deformation resistance at high *** as-deposited specimen exhibited intergranular fracture at 473 K,with cracks preferring to propagate along the aggregated ***,crack propagation proceeded in the sections with more pores in the heat-treated *** approach may provide a valid option for achieving alu-minum alloys with excellent high-temperature mechanical properties.

关键词： Laser-arc hybrid additive manufacturing Al-Zn-Mg-Cu alloy High-temperature strength Heat treatment,Microstructure evolution

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Kinematic calibration method with high measurement efficiency and robust identification for hybrid machine tools

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Chinese Journal of Aeronautics 2024年第3期37卷 468-482页

作者： Liping WANG Mengyu LI Guang YU Weitao LI Xiangyu KONG State Key laboratory of Tribology Department of Mechanical EngineeringTsinghua UniversityBeijing 100084China Beijing Key laboratory of precision/Ultra-precision manufacturing Equipment and Control Beijing 100084China

Geometric error is the main factor affecting the machining accuracy of hybrid machine *** calibration is an effective way to improve the geometric accuracy of hybrid machine *** necessity to measure both position and orientation at each pose,as well as the instability of identification in case of incomplete measurements,severely affects the application of traditional calibration *** this study,a kinematic calibration method with high measurement efficiency and robust identification is proposed to improve the kinematic accuracy of a five-axis hybrid machine ***,the configuration is introduced,and an error model is ***,by investigating the mechanism error characteristics,a measurement scheme that only requires tool centre point position error measurement and one alignment operation is ***,by analysing the effects of unmeasured degrees of freedom(DOFs)on other DOFs,an improved nonlinear least squares method based on virtual measurement values is proposed to achieve stable parameter identification in case of incomplete measurement,without introducing additional ***,the proposed calibration method is verified through simulations and *** proposed method can efficiently accomplish the kinematic calibration of the hybrid machine *** accuracy of the hybrid machine tool is significantly improved after calibration,satisfying actual aerospace machining requirements.

关键词： Hybrid machine tool Calibration Measurement scheme Improved nonlinear least squares method Virtual measurement values

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A new 3D plastoelastohydrodynamic lubrication model for rough surfaces

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Friction 2024年第6期12卷 1176-1193页

作者： Shengyu YOU Jinyuan TANG Qiang WANG State Key laboratory of precision manufacturing for Extreme Service Performance Central South UniversityChangsha 410083China

Plastoelastohydrodynamic lubrication of rough surfaces(R-PEHL)is a cutting-edge area of research in interface fluid-structure coupling *** existing R-PEHL model calculates the elastic-plastic deformation of rough surface by the Love equation in a semi-infinite space smooth surface,which deviates from the actual ***,it is an innovative work to study the exact solution of elastic-plastic deformation of rough surface and its influence on the solution results of R-PEHL *** this paper,a new contact calculation model of plastoelastohydrodynamic lubrication(PEHL)with three-dimensional(3D)rough surface is proposed by integrating numerical method of EHL and finite element *** new model eliminates an original error introduced by the assumption of semi-infinite space in contact calculation,providing wide applicability and high *** the given rough surfaces and working conditions,the study reveals that:(1)the oil film pressure calculated by the new model is lower than that of the smooth surface in semi-infinite space by 200–800 MPa;(2)the Mises stress of the new model is 2.5%–26.6%higher than that of the smooth surface in semi-infinite space;(3)compared with the semi-infinite space assumption,the rough surface plastic deformation of the new model is increased by 71%–173%,and the local plastic deformation singularity may appear under the semi-infinite space assumption;(4)the plastic deformation caused by the first contact cycle on the rough surface of the new model accounts for 66.7%–92.9%of the total plastic deformation,and the plastic deformation of the semi-infinite space accounts for 50%–83.3%.This study resolves the contradiction between the smooth surface assumption and the rough surface in the existing R-PEHL model,establishing a solid logic foundation for the accurate solution of R-PEHL model.

关键词： rough surface plastoelastohydrodynamic lubrication(PEHL) asperity plastic deformation semi-infinite space

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Improving surface integrity of micro-holes in ECDM using ultrahigh-speed rotary of tool cathode and non-water-based electrolyte

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Chinese Journal of Aeronautics 2024年第5期37卷 506-519页

作者： Jiwen SHEN Weijing KONG Zhengyang XU Yongbin ZENG Jiangsu Key laboratory of precision and Micro-manufacturing Technology Nanjing University of Aeronautics and AstronauticsNanjing 210016China

The surface integrity of metal micro-hole structures produced by electrochemical discharge machining is unsatisfactory owing to the insufficient reaction area and strength of electrolysis action.A novel ultrahigh-speed Rotary Electrochemical Discharge Machining(R-ECDM)using non-water-based electrolyte is proposed to improve surface integrity by changing the breakdown medium of spark discharge and increasing the reaction area and strength of electrolysis.A mathematical model was developed to establish the relationship between rotational speed and forces acting on the *** on the magnitude of forces,controlling rotational speed changed the behavior and departure radius of bubbles on the cathode ***-speed photographs validate that,in the mathematical model,the number and departure radius of bubbles on the cathode surface gradually decrease with the increase of rotational *** experimental results show that the roughness(Ra)of the micro-hole sidewall decreases from 2.54μm to 0.20μm when the rotational speed increases from 500 r/min to 40000 r/*** length loss and wear ratio of the cathode are only 9.75μm and 6.5%,***,the micro-holes array with recast-free and surface roughness of 0.20μm is fabricated,demonstrating that the proposed approach contributes to improving surface integrity of metal micro-holes.

关键词： Electrochemical discharge machining Micro-holes Recast layer Ultrahigh-speed rotary Bubbles Force analysis Non-water-based solution

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Tactile-sensing-based robotic grasping stability analysis

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Science China(Technological Sciences) 2024年第6期67卷 1817-1828页

作者： HUANG YanJiang WANG HaoNan ZHANG XianMin Guangdong Provincial Key laboratory of precision Equipment and manufacturing Technology South China University of TechnologyGuangzhou510640China

Tactile signals play a crucial role in enabling robots to successfully manipulate unfamiliar *** robots to grasp unknown objects securely and without causing damage,it is essential that they can analyze grasping stability in real time through tactile signals and respond *** study introduces a novel method for analyzing the stability of robotic hand grasping,utilizing the Wilcoxon signed rank *** efficacy of this method is demonstrated through its static and dynamic performance,and evaluated across a series of *** findings of this research highlight the method’s ability to accurately detect when an object begins to slip from the robot’s *** this method allows the gripper to maintain a secure hold on objects by applying the minimal necessary *** also enables the gripper to dynamically adjust the force it applies in real time,thus preventing the object from slipping during the movement of the robotic ***,the gripper demonstrates the ability to stably grasp objects of varied weights and with unknown characteristics,showcasing the versatility and effectiveness of the proposed method.

关键词： grasping stability manipulation tactile sensors

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Atomistic understanding of rough surface on the interfacial friction behavior during the chemical mechanical polishing process of diamond

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Friction 2024年第6期12卷 1119-1132页

作者： Song YUAN Xiaoguang GUO Hao WANG Renke KANG Shang GAO State Key laboratory of High-performance precision manufacturing Dalian University of TechnologyDalian 116024China

The roughness of the contact surface exerts a vital role in *** is still a significant challenge to understand the microscopic contact of the rough surface at the atomic ***,the rough surface with a special root mean square(RMS)value is constructed by multivariate Weierstrass–Mandelbrot(W–M)function and the rubbing process during that the chemical mechanical polishing(CMP)process of diamond is mimicked utilizing the reactive force field molecular dynamics(ReaxFF MD)*** is found that the contact area A/A0 is positively related with the load,and the friction force F depends on the number of interfacial bridge *** the surface roughness will increase the friction force and friction *** model with low roughness and high lubrication has less friction force,and the presence of polishing liquid molecules can decrease the friction force and friction *** RMS value and the degree of damage show a functional relationship with the applied load and lubrication,i.e.,the RMS value decreases more under larger load and higher lubrication,and the diamond substrate occurs severer damage under larger load and lower *** work will generate fresh insight into the understanding of the microscopic contact of the rough surface at the atomic level.

关键词： diamond random roughness reactive force field molecular dynamics(ReaxFF MD) friction Weierstrass-Mandelbrot(W-M)function chemical mechanical polishing(CMP)

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Precise measurement of geometric and physical quantities in cutting tools inspection and condition monitoring: A review

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Chinese Journal of Aeronautics 2024年第4期37卷 23-53页

作者： Wenqi WANG Wei LIU Yang ZHANG Yang LIU Peidong ZHANG Zhenyuan JIA State Key laboratory of High-Performance precision manufacturing Dalian University of TechnologyDalian 116024China

As one of the most important terminals in machining, cutting tools have been widely used for components manufacturing in aerospace and other industries. The quality of these components and processing efficiency are closely linked to the performance of cutting tools. Therefore, it is essential and critical to inspect the cutting tools and monitor the condition during the stage of manufacturing and machining. This review aims to discuss and summarize the key problems, methods,and techniques from the perspective of the tool geometric and the physical quantities measurement,including machine vision, physical sensors and data processing. It is worth mentioning that we focus on the topic of precision measurement methods and discuss universal solutions by identifying the common characteristics of the measured quantities. Eventually, the challenges and future trends for the development of in-depth research and practical applications are concluded. The research and application of precise measurement techniques for geometric and physical quantities will better promote the development of intelligent manufacturing.

关键词： Cutting tools Mechanical measurement Machine vision Physical sensors Tool condition monitoring

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

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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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Biomimetic soft robotic wrist with 3-DOF motion and stiffness tunability based on ring-reinforced pneumatic actuators and a particle jamming joint

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Science China(Technological Sciences) 2024年第3期67卷 774-790页

作者： HU TeTe LU XinJiang YI Jian WANG YuHui XU Du State Key laboratory of precision manufacturing for Extreme Service Performance School of Mechanical and Electrical EngineeringCentral South UniversityChangsha 410083China

The human wrist, a complex articulation of skeletal muscles and two-carpal rows, substantially contributes to improvements in maneuverability by agilely performing three-degree-of-freedom(3-DOF) orienting tasks and regulating stiffness according to variations in interaction forces. However, few soft robotic wrists simultaneously demonstrate dexterous 3-DOF motion and variable stiffness;in addition, they do not fully consider a soft-rigid hybrid structure of integrated muscles and two carpal *** this study, we developed a soft-rigid hybrid structure to design a biomimetic soft robotic wrist(BSRW) that is capable of rotating in the x and y directions, twisting around the z-axis, and possessing stiffness-tunable capacity. To actuate the BSRW, a lightweight soft-ring-reinforced bellows-type pneumatic actuator(SRBPA) with large axial, linear deformation(η_(lcmax)=70.6%,η_(lemax)=54.3%) and small radial expansion(η_(demax)=3.7%) is designed to mimic the motion of skeletal muscles. To represent the function of two-carpal rows, a compact particle-jamming joint(PJJ) that combines particles with a membrane-covered ballsocket mechanism is developed to achieve various 3-DOF motions and high axial load-carrying capacity(>60 N). By varying the jamming pressure, the stiffness of the PJJ can be adjusted. Finally, a centrally positioned PJJ and six independently actuated SRBPAs, which are in an inclined and antagonistic arrangement, are sandwiched between two rigid plates to form a flexible,stable, and compact BSRW. Such a structure enables the BSRW to have a dexterous 3-DOF motion, high load-carrying ability,and stiffness tunability. Experimental analysis verify 3-DOF motion of BSRW, producing force of 29.6 N and 36 N and torque of2.2 Nm in corresponding rotations. Moreover, the range of rotational angle and stiffness-tuning properties of BSRW are studied by applying jamming pressure to the PJJ. Finally, a system combining a BSRW and a soft enclosing gripper is proposed to demo

关键词： pneumatic soft actuators particle jamming robotic wrist soft robotics stiffness-tunable

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Precipitates Generation Mechanism and Surface Quality Improvement for Aluminum Alloy 6061 in Diamond Cutting

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Journal of Wuhan University of Technology(Materials Science) 2024年第1期39卷 150-159页

作者：王海龙 DENG Wenping 王素娟 State Key laboratory of precision Electronic manufacturing Technology and Equipment Guangdong University of TechnologyGuangzhou 510006China Guangdong Provincial Key laboratory of Micro-Nano manufacturing Technology and Equipment School of Electromechanical EngineeringGuangdong University of TechnologyGuangzhou 510006China

To improve the surface quality for aluminum alloy 6061(Al6061) in ultra-precision machining, we investigated the factors affecting the surface finish in single point diamond turning(SPDT)by studying influence of the precipitates generation of Al6061 on surface integrity and surface *** on the Johnson-Mehl-Avrami solid phase transformation kinetics equation, theoretical and experimental studies were conducted to build the relationship between the aging condition and the type, size and number of the precipitates for Al6061. Diamond cutting experiments were conducted to machine Al6061 samples under different aging conditions. The experimental results show that, the protruding on the chip surface is mainly Mg_(2)Si and the scratches on the machined surface mostly come from the iron-containing phase(α-, β-AlFeSi).Moreover, the generated Mg_(2)Si and α-, β-AlFeSi affect the surface integrity and the diamond turned surface roughness. Especially, the achieved surface roughness in SPDT is consistent with the variation of the number of AlFeSi and Mg_(2)Si with the medium size(more than 1 μm and less than 2 μm) in Al6061.

关键词： Al6061 precipitates aging treatment diamond cutting surface roughness

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