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Article
Engineering, Mechanical
An Zhou et al.
Summary: This paper investigates the nano-tribological behaviors and deformation process of Cu-Ni alloy using molecular dynamics simulation. The effects of pressed depth, alloy composition, and sliding distance on friction state, dislocation density, and von-Mises strain stress are comprehensively studied. The results show that a larger pressed depth leads to more lattice defects and higher transverse force, increasing Cu content enhances stacking fault and dislocation density, and longer sliding distance induces more plastic deformation and wear atoms. Cu atoms improve the deformation resistance of Cu-Ni alloy. This study enriches the understanding of nano-tribological behavior and deformation mechanism of Cu-Ni alloy during the ultraprecision process.
TRIBOLOGY INTERNATIONAL
(2023)
Article
Engineering, Mechanical
Dongling Yu et al.
Summary: A three-dimensional model was established to study the deformation and damage of nano-twin 6H-SiC after friction. It was found that the barrier formed by layered faults can obstruct stress propagation and hinder the formation and expansion of dislocations. The strength of the twins exhibits Hall-Petch phenomenon, with the highest strength observed at a thickness of 10.3 nm. The twin boundary serves as the initiation point for deformation damage, and the damage increases with the thickness of the twin.
TRIBOLOGY INTERNATIONAL
(2023)
Article
Engineering, Mechanical
Zhigang Dong et al.
Summary: This study conducted a molecular dynamics simulation of nano-cutting tungsten and proposed a method to determine the minimum uncut chip thickness. The effects of chip formation on the removal mechanism of tungsten were also studied. It was found that the critical cutting depth without chip affected the surface quality and subsurface damage. The plastic deformation mechanism depended on the presence of chip during the cutting process.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2023)
Article
Automation & Control Systems
Zhiwei Yu et al.
Summary: Tungsten alloy is widely used in cutting-edge industries such as military, aerospace, and nuclear energy due to its excellent performance. However, the inherent characteristics of tungsten alloy, such as high hardness, high strength, and poor plastic deformation ability, result in challenges during the cutting process. Thus, it is crucial to conduct research on tungsten alloy cutting technology to enhance its application. This review focuses on the progress in cutting process technology, including optimization of cutting parameters, new cutting methods and devices, cutting fluid technology, as well as the types of cutting tools, tool coatings, and composite cutting technologies. The future prospects of tungsten alloy cutting technology are also discussed.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Mechanical
Changlin Liu et al.
Summary: This paper explores the formation mechanism of crystal defects in single-crystal silicon during elliptical vibration cutting (EVC) using molecular dynamics simulation. The study finds that the cutting stage in EVC greatly influences the surface morphology, including elastic recovery and side flow. The preferred slip motion during subsurface damage formation is distinct in the extrusion and shear stage. The influence of cutting temperature and speed on crystal defects formation is also investigated, revealing the increase in proportion of Shockley partial dislocations at elevated temperature and the suppression of crystal defects generation with higher speed ratio.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2023)
Article
Materials Science, Multidisciplinary
Gan Li et al.
Summary: Ultrasonic elliptical vibration cutting is widely used in precision cutting of difficult-to-machine metal materials. This paper uses a rigid/viscoplastic rod model to simulate the cutting horn in the cutting device and analyzes the factors influencing the amplitude-frequency response of the horn. The influence of cutting speed and cutting depth on cutting chatter was studied through experiments, and the impact of cutting chatter on cutting surface morphology and tool wear was also investigated. The results show that the cutting speed affects the excitation frequency of the horn, and a reasonable cutting speed can prevent cutting chatter and horn resonance. The cutting depth affects the excitation amplitude and amplifies the vibration amplitude during chatter or resonance. Experimental results demonstrate that suppressing cutting chatter can significantly improve cutting surface quality and reduce diamond tool wear in ultrasonic elliptical vibration cutting of heavy tungsten alloy.
Article
Engineering, Manufacturing
Qingxuan Zhao et al.
Summary: The direction of ultrasonic vibration has a significant influence on chip formation in turning process. Ultrasonic vibration in the cutting speed direction can effectively suppress serrated chips and promote the formation of smooth and continuous chips, while ultrasonic vibration in the cutting depth direction has the opposite effect. When the tool is superimposed with two-way vibration, the chip morphology formed by the elliptical trajectory is smoother and more continuous, resulting in the highest strain rate and the lowest cutting force. The advantages of elliptical trajectory machining also include reducing surface roughness compared to conventional cutting and cutting with variable phase difference.
JOURNAL OF MANUFACTURING PROCESSES
(2023)
Article
Engineering, Manufacturing
Xiaoliang Liang et al.
Summary: This study clarifies the differences between the micro/nano incremental material removal mechanisms of conventional cutting (CC) and high-frequency ultrasonic vibration-assisted cutting (HFUVAC), and compares their machinability advantages and microstructure features through ultra-precision cutting experiments. The results indicate that HFUVAC achieves superior machinability by reducing cutting force, reducing tool wear, suppressing surface defects, and transitioning chips from a discontinuous quasi-shear state to a continuous multiple-shear state. The study provides guidance for improving surface quality and optimizing the cutting speed to vibration frequency ratio to enhance efficiency.
INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE
(2023)
Article
Engineering, Manufacturing
Weihai Huang et al.
Summary: In this study, the tool-workpiece interaction mechanisms in cutting curved microstructures on 4H-SiC (0001) were explored through ultraprecision diamond turning. It was found that microcracks easily occurred in the feed-in/cut-in area of the micro-dimples due to large friction-induced tensile stress. Dimples located on different cleavage directions exhibited varying tendencies to cause surface cracking and had different subsurface damage characteristics.
INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE
(2023)
Article
Engineering, Mechanical
Hao Wang et al.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2023)
Review
Engineering, Manufacturing
Liang Zhao et al.
Summary: Ultra-precision diamond cutting is a promising machining technique that can achieve ultra-smooth surfaces for various materials. This review provides a comprehensive overview of recent advancements in numerical simulations for material-oriented diamond cutting. Different machining phenomena, such as anisotropy cutting behavior, thermo-mechanical coupling, cutting responses of individual phases in composite materials, and the impact of external energetic fields, are systematically summarized and discussed using multiscale simulations. The development of novel physics-based numerical models and insights into the future of advanced simulation techniques are also highlighted.
INTERNATIONAL JOURNAL OF EXTREME MANUFACTURING
(2023)
Review
Engineering, Manufacturing
Jianqiu Zhang et al.
Summary: High-speed machining (HSM) has been extensively studied and has potential applications in various industries. However, the underlying mechanisms of HSM, specifically in adiabatic shear band (ASB) onset and material metallurgical microstructural evolutions, have not been formally reviewed. This article focuses on the solid mechanics framework of ASB onset and material metallurgical changes in HSM, considering factors like machining speed and their effects on ASB formation and material damage. Proposed mechanisms for the observed phenomena in HSM include variations in the white layer thickness of ductile materials, which contribute to a better understanding of HSM.
INTERNATIONAL JOURNAL OF EXTREME MANUFACTURING
(2023)
Article
Engineering, Mechanical
Jian Guo et al.
Summary: This study investigates temperature-dependent material attrition and subsurface lattice damage of single-crystal AlN at different scratching depths/forces using molecular dynamics simulation. A monolayer precision of AlN removal is achieved based on temperature-dependent critical conditions. The number of worn atoms increases exponentially with increasing normal force, influenced by temperature. A wear coefficient normalized with the tangential contact area, K/Atang, is developed to interpret the removal efficiency of AlN substrate with diamond abrasive, independent of load and temperature.
TRIBOLOGY INTERNATIONAL
(2023)
Article
Computer Science, Artificial Intelligence
Yanan Pan et al.
Summary: This paper uses ultrasonic elliptical vibration cutting technology for ultra-precision machining of tungsten heavy alloy, and improves the prediction model of surface roughness through deep learning, achieving online prediction of cutting surface roughness.
JOURNAL OF INTELLIGENT MANUFACTURING
(2022)
Article
Chemistry, Physical
Qiang Lin et al.
Summary: This paper presents a reactive molecular dynamics study on the nanoscale wear mechanism of diamond under different temperatures. The research reveals a critical temperature that significantly accelerates the mechanical failure and wear of diamond. The study also analyzes the effects of thermal stress and friction-induced stress on the diamond structure.
APPLIED SURFACE SCIENCE
(2022)
Article
Chemistry, Physical
Shuo Zhang et al.
Summary: Compared with conventional orthogonal cutting, this study systematically investigates the oblique nano-cutting of 6H-SiC by tilting the tool at different angles through molecular dynamics simulations. The deformation mechanism, surface deformation, and cutting force variation are studied, and the transition path of amorphization is clarified. Dislocation analysis reveals that basal dislocation systems dominate the behavior, while in oblique nano-cutting, the basal 1/3 < 1 (1) over bar 00> Shockley partial dislocation of 6H-SiC is more activated due to the inclined-cutting-edge-derived shear stress.
APPLIED SURFACE SCIENCE
(2022)
Article
Engineering, Manufacturing
Hongguang Liu et al.
Summary: This paper summarizes the state of the art in modeling approaches for the effect of microstructures and their evolution during metal-cutting processes, analyzes the advantages and drawbacks, and provides future research directions.
INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE
(2022)
Article
Automation & Control Systems
Yanan Pan et al.
Summary: This study focuses on the surface morphology evolution and microstructural transformation of 95W-3.5Ni-1.5Fe alloy in ultrasonic elliptical vibration cutting. It was found that a nanometer-level roughness surface can be generated under specific processing conditions. A multiscale theoretical simulation framework and an ultra-precision machining simulation model were developed to reveal the influence of different machining conditions on surface formation and dislocation density distribution.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Materials Science, Multidisciplinary
Zhiwei Xu et al.
Summary: In this research, a comprehensive investigation was conducted on the sustainable production mechanisms of tungsten heavy alloys through experimental tests and analysis of surface morphologies, subsurface microstructures, and micro-tool wear features. The study found that high-performance surfaces can be achieved and flank wear can be suppressed by selecting appropriate laser-assisted micro-milling conditions.
MATERIALS & DESIGN
(2022)
Article
Engineering, Mechanical
Hao Wang et al.
Summary: Although the effects of tool geometry on the removal behavior of many metals have been studied, the same is not true for tungsten due to its higher brittleness. Here, a molecular dynamics simulation model was established to investigate the removal behavior during nano-cutting of tungsten with different tool geometries. The results showed that certain tool geometries, such as larger positive rake angle or clearance angle and smaller edge radius, were beneficial for reducing surface roughness, elastic recovery, subsurface damage layer thickness, cutting force, cutting temperature, friction coefficient, and maximum stress. The research findings provide a theoretical basis for the micro removal behavior of tungsten and can serve as a reference for tool design in nano-cutting.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2022)
Article
Engineering, Mechanical
Long Guo et al.
Summary: Tungsten is a promising candidate material for future fusion reactors. The study finds that the habit plane and plasticity of tungsten with a 1/2 < 111 > crystallographic orientation are strongly influenced by shock waves. A new rotation mechanism is proposed to predict the changing trend of the habit plane of dislocation loops.
INTERNATIONAL JOURNAL OF PLASTICITY
(2022)
Article
Engineering, Manufacturing
Hao Wang et al.
Summary: This study used molecular dynamics simulation to investigate the evolution mechanism of subsurface damage in nano-cutting of single-crystal tungsten, as well as the effects of cutting force on subsurface damage. The results revealed the presence of various forms of damage, including atomic cluster, vacancy defect, V-shaped dislocation, stair-rod dislocation, and dislocation ring. The cutting force and its fluctuation significantly influenced the subsurface damage, such as the number of surface defect atoms, dislocation density, and thickness of the subsurface damage layer. It is important to select a smaller cutting depth and appropriate cutting speed to minimize subsurface damage during nano-cutting of tungsten components.
JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME
(2022)
Article
Materials Science, Multidisciplinary
Jinxuan Bai et al.
Summary: Tungsten heavy alloy with high-precision and ultra-fine grained surface shows promise for applications in nuclear protection and precision instruments. The use of ultrasonic elliptic vibration cutting method resulted in excellent machined surface quality and confirmed the generation of an ultra-fine grained structure through microstructural analysis.
MATERIALS & DESIGN
(2022)
Article
Engineering, Mechanical
Sen Yin et al.
Summary: A high-performance ultrasonic elliptical vibration cutting system was developed to solve the precision machining problem of tungsten heavy alloy. The system's technical capability was verified through cutting experiments, providing an optimization basis for improving the machining quality of curved surface components. The study is important for the nuclear industry and precision instruments.
FRONTIERS OF MECHANICAL ENGINEERING
(2022)
Article
Materials Science, Multidisciplinary
Jennire V. Nava et al.
Summary: This study analyzed the grinding behavior of tungsten ore from the Barruecopardo Mine in Spain, and developed a protocol to study the influence of operational and geometallurgical variables on grinding kinetics, as well as determine breakage probability and breakage function. The research findings are helpful for optimizing grinding operations and reducing energy consumption.
Review
Engineering, Manufacturing
Tao Zhang et al.
Summary: This paper reviews the brittle-ductile transition (BDT) in extreme manufacturing, analyzes the factors affecting it, and discusses the mechanisms behind it. It suggests that the competition between plastic deformation and crack propagation determines the transition between brittleness and ductility. The brittleness or ductility of the machined material should be regulated by deformation scale, deformation temperature, and machining speed to benefit specific manufacturing processes.
INTERNATIONAL JOURNAL OF EXTREME MANUFACTURING
(2021)
Article
Chemistry, Physical
Wenkun Xie et al.
APPLIED SURFACE SCIENCE
(2020)
Article
Materials Science, Multidisciplinary
Yuan Zhang et al.
MATERIALS & DESIGN
(2020)
Review
Engineering, Manufacturing
Zhichao Yang et al.
INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE
(2020)
Article
Engineering, Manufacturing
Zige Tian et al.
INTERNATIONAL JOURNAL OF EXTREME MANUFACTURING
(2020)
Article
Materials Science, Multidisciplinary
Xiaodan Zhang et al.
Review
Engineering, Manufacturing
Saurav Goel et al.
INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE
(2015)
Article
Nanoscience & Nanotechnology
G. Dini et al.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2010)
