Review of field-assisted ultraprecision machining difficult-to-machine materials

Xu, Jianfeng; Huang, Kai; Zheng, Zhengding; Lin, Chuangting; Zhang, Jianguo; Xiao, Junfeng; Chen, Xiao

doi:10.1360/sst-2021-0393

Cited by 8 publications

(2 citation statements)

References 107 publications

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“…Ultrasonic machining technology is widely used in the field of ultra-precision machining of difficult-to-machine materials [ 1 , 2 , 3 ]. A series of ultrasonic-assisted machining technology has been developed by combining ultrasonic technology with cutting, grinding, and other traditional processing technologies [ 4 , 5 , 6 ].…”

Section: Introductionmentioning

confidence: 99%

Material Removal Characteristics of Spherical-Array-Focused Ultrasonic Abrasive Machining

Wang

Yuan

et al. 2023

Micromachines

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To improve the ultrasonic energy and realize far-field ultrasonic abrasive machining of complex surfaces, a spherical-array-focused ultrasonic abrasive machining system was established. By combining ultrasonic field simulation, detection and a single-factor experiment, the influences of the ultrasonic generator current, abrasive concentration, and particle size on the material removal properties and surface quality evolution of quartz glass were investigated. When the current was less than 0.4 A, the material removal showed plastic removal at the nanoscale. When the current was more than 0.5 A, the cavitation phenomenon formed micron-scale impact removal traces on the workpiece surface. The increase in abrasive concentration increased the impact density and material removal rate, while excessive abrasive concentration increased the impeding effect between abrasive particles and reduced the material removal rate. Moreover, the increase in abrasive particle concentration enhanced heterogeneous cavitation nucleation, promoted the removal of abrasive impact materials under the action of a cavitation jet, and inhibited the removal of direct surface cavitation. The abrasive particle size affects the heterogeneous cavitation nucleation and the acceleration of the cavitation jet on abrasive particles, which affects the material removal rate and surface quality. By controlling the energy of the focused ultrasound and abrasive parameters, the plastic or brittle domain removal of quartz glass can be achieved at the micro- and nanoscales.

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Section: Introductionmentioning

confidence: 99%

Material Removal Characteristics of Spherical-Array-Focused Ultrasonic Abrasive Machining

Wang

Yuan

et al. 2023

Micromachines

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“…The feasibility of the LADT method has been verified in various hard and brittle materials, including silicon [10], zinc selenide [11], and tungsten carbide [12]. With the laser in-process heating assistance, diamond tool wear, finish quality, subsurface damage, and machining efficiency can be effectively improved compared with the conventional single-point diamond turning method [13]. However, it is challenging to ensure the sub-micron form accuracy of the workpiece using the LADT method.…”

Section: Introductionmentioning

confidence: 99%

Pre-Compensation of Thermal Error for Laser-Assisted Diamond Turning

You,

Liu,

Yan

et al. 2023

Micromachines

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The laser-assisted diamond turning (LADT) method can effectively improve the machinability of hard and brittle materials based on the laser heating effect, resulting in prolonged diamond tool life and better surface integrity. However, due to the incomplete absorption of laser beam energy within the workpiece cutting zone, simultaneous heating of the tool holder occurs, resulting in a structural thermal expansion that affects the workpiece form accuracy. In this article, the form accuracy of a LADT-machined workpiece was systematically studied. Accurate calculations of the tool shank and tool holder thermal fields and thermal expansion were performed using thermodynamic coupled finite element analysis. In addition, the LADT tool path was precisely pre-compensated by taking into account the structure expansion. The experimental results demonstrate that the form accuracy can be significantly improved with a pre-compensated tool path, which provides crucial technical support for achieving a high-precision finish on optical elements using the LADT method.

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A review of research on material removal mechanisms for laser-assisted machining of difficult-to-machine materials

Xiao,

Wang,

Zhu

et al. 2023

Surf. Sci. Tech.

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With the development of technology in aerospace, medical devices and other fields, high-performance difficult-to-machine materials have been widely used in these fields due to their good comprehensive mechanical properties. However, when using traditional machining methods, it is difficult to ensure the machining accuracy and surface quality, and at the same time, there are problems such as serious tool wear and low machining efficiency. Laser-assisted machining (LAM) technology is an advanced manufacturing process that softens the material in the machining area through the preheating effect of the laser, thus reducing the surface hardness of the material and improving the machinability of the material, which has the advantages of high efficiency and economy in machining difficult-to-machine materials. This paper introduces the common methods of establishing thermal models and simulation modeling of removal behavior in the LAM material removal process, summarizes the research progress on the removal behavior of LAM processing of various difficult-to-machine materials, and analyzes the shortcomings and challenges of the current research. Finally, the key issues of LAM material removal mechanism are proposed, and the development direction of LAM material removal technology is envisioned in order to provide a reference for the research and development in this field.

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Review of field-assisted ultraprecision machining difficult-to-machine materials

Cited by 8 publications

References 107 publications

Material Removal Characteristics of Spherical-Array-Focused Ultrasonic Abrasive Machining

Material Removal Characteristics of Spherical-Array-Focused Ultrasonic Abrasive Machining

Pre-Compensation of Thermal Error for Laser-Assisted Diamond Turning

A review of research on material removal mechanisms for laser-assisted machining of difficult-to-machine materials

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