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The heat generated during the cutting process of titanium alloys and superalloys is a significant limitation that affects machining quality. Excessive heat can accelerate tool wear, increase cutting forces, alter material properties, and decrease productivity. To address this issue, alternative cooling techniques have been suggested to minimize heat generation during cutting. Among these alternatives, internal cooling techniques have emerged as a more efficient and cost-effective solution. This paper provides a comprehensive review of internal cooling techniques in the cutting process, including their effects on cutting fluid flow, chip formation, cutting temperature, cutting forces, surface roughness, tool wear, and chip morphology. The paper also presents methods to enhance cooling and lubrication performance by optimizing the internal cooling channels and outlet nozzles of cutting tools, as well as selecting appropriate fluid supply pressure. Additionally, the paper highlights important considerations when using internal cooling techniques and proposes future directions for their development, taking into account existing challenges.
The heat generated during the cutting process of titanium alloys and superalloys is a significant limitation that affects machining quality. Excessive heat can accelerate tool wear, increase cutting forces, alter material properties, and decrease productivity. To address this issue, alternative cooling techniques have been suggested to minimize heat generation during cutting. Among these alternatives, internal cooling techniques have emerged as a more efficient and cost-effective solution. This paper provides a comprehensive review of internal cooling techniques in the cutting process, including their effects on cutting fluid flow, chip formation, cutting temperature, cutting forces, surface roughness, tool wear, and chip morphology. The paper also presents methods to enhance cooling and lubrication performance by optimizing the internal cooling channels and outlet nozzles of cutting tools, as well as selecting appropriate fluid supply pressure. Additionally, the paper highlights important considerations when using internal cooling techniques and proposes future directions for their development, taking into account existing challenges.
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The tube spinning process has attracted much attention because of its simple tooling and good surface finish. This review presents a comprehensive survey of the tube spinning process with a focus on different tube blank materials and spinning methods. The review aims to elaborate the research status of tube spinning process from the aspects of tube material, spinning method and processing performance, and act as a guide for researchers working on tube production and spinning process. In addition, the spinning process will produce large plastic deformation, which will lead to the change of the microstructure of the tube and change its mechanical properties. Therefore, the relationship between the mechanical properties of the tube blank and the spinning parameters is comprehensively expounded from the aspects of yield strength, elongation and material microstructure, and the element diffusion and interface bonding mechanism in the spinning process of the composite tubes are emphatically introduced. In particular, the latest development and trend of composite materials and composite spinning process in tube blank spinning process are discussed. The challenges and prospects of the development of the tube spinning process are put forward, and the direction for future research is pointed out.
The tube spinning process has attracted much attention because of its simple tooling and good surface finish. This review presents a comprehensive survey of the tube spinning process with a focus on different tube blank materials and spinning methods. The review aims to elaborate the research status of tube spinning process from the aspects of tube material, spinning method and processing performance, and act as a guide for researchers working on tube production and spinning process. In addition, the spinning process will produce large plastic deformation, which will lead to the change of the microstructure of the tube and change its mechanical properties. Therefore, the relationship between the mechanical properties of the tube blank and the spinning parameters is comprehensively expounded from the aspects of yield strength, elongation and material microstructure, and the element diffusion and interface bonding mechanism in the spinning process of the composite tubes are emphatically introduced. In particular, the latest development and trend of composite materials and composite spinning process in tube blank spinning process are discussed. The challenges and prospects of the development of the tube spinning process are put forward, and the direction for future research is pointed out.
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Arc wire-based Direct Energy Deposition (DED) technology is an essential additive manufacturing process that exhibits a high deposition rate and heat accumulation. This technology is advantageous due to its efficient production at a low cost. The process utilizes an electric arc for heat source and metal wire for feed material. After path planning, it creates three-dimensional metal parts layer by layer. In order to prevent defects from affecting the service condition and lifespan of the parts, it is crucial to focus on the evolution of the microstructure and the enhancement of the mechanical properties during the deposition process. During metal parts manufacturing using Arc wire-based DED, defects such as residual stresses, porosity, deformation, and cracking are generated due to the complex thermal cycle and high heat input. This paper provides a concise overview of the process and methodology involved in Arc wire-based DED, along with an analysis of the resulting microstructure and material properties. This review also outlines means of controlling the heat input, as well as pre-treatment, in-process, and post-treatment methods for controlling the defects and microstructure to improve the properties of the workpieces. Finally, the paper offers insights into achieving high-quality, defect-free workpieces using Arc wire-based DED and provides recommendations for future DED development.
Arc wire-based Direct Energy Deposition (DED) technology is an essential additive manufacturing process that exhibits a high deposition rate and heat accumulation. This technology is advantageous due to its efficient production at a low cost. The process utilizes an electric arc for heat source and metal wire for feed material. After path planning, it creates three-dimensional metal parts layer by layer. In order to prevent defects from affecting the service condition and lifespan of the parts, it is crucial to focus on the evolution of the microstructure and the enhancement of the mechanical properties during the deposition process. During metal parts manufacturing using Arc wire-based DED, defects such as residual stresses, porosity, deformation, and cracking are generated due to the complex thermal cycle and high heat input. This paper provides a concise overview of the process and methodology involved in Arc wire-based DED, along with an analysis of the resulting microstructure and material properties. This review also outlines means of controlling the heat input, as well as pre-treatment, in-process, and post-treatment methods for controlling the defects and microstructure to improve the properties of the workpieces. Finally, the paper offers insights into achieving high-quality, defect-free workpieces using Arc wire-based DED and provides recommendations for future DED development.
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Additive Manufacturing (AM), commonly known as 3D printing, over three decades, emphasizing its transformative ability to create intricate structures in a single unit. The growing popularity of AM is attributed to continuous technological advancements and its application across diverse materials, responding to the demand for personalized products, shorter development cycles, sustainability, and new business models. Despite AM's strengths, the limitations of materials used in the process prompt the integration of intelligent materials, particularly in the emerging field of 4D printing. The focus shifts to intelligent materials, also known as smart materials, which respond to external stimuli, offering controlled transformations or shape changes post-fabrication. The narrative explores programmable matter, or 4D printing, where materials exhibit time-induced dynamics, introducing a fourth dimension to AM. Intelligent materials such as piezoelectric, shape-memory, giant magnetostrictive, and nanomaterials extend the scope of applications from sensors to artificial muscles. The review discusses diverse 3D printing technologies in conjunction with intelligent materials, envisioning a future where these materials redefine additive manufacturing landscapes. AM technologies showcase their compatibility with intelligent materials and their potential to revolutionize various industries. The compatibility of intelligent materials with these technologies opens avenues for creating complex, functional, and customized objects with improved mechanical, thermal, and electrical qualities. 4D printing and the fusion of intelligent materials with bioinspired design principles offer a glimpse into the future of adaptive and functionally superior 3D-printed objects.
Additive Manufacturing (AM), commonly known as 3D printing, over three decades, emphasizing its transformative ability to create intricate structures in a single unit. The growing popularity of AM is attributed to continuous technological advancements and its application across diverse materials, responding to the demand for personalized products, shorter development cycles, sustainability, and new business models. Despite AM's strengths, the limitations of materials used in the process prompt the integration of intelligent materials, particularly in the emerging field of 4D printing. The focus shifts to intelligent materials, also known as smart materials, which respond to external stimuli, offering controlled transformations or shape changes post-fabrication. The narrative explores programmable matter, or 4D printing, where materials exhibit time-induced dynamics, introducing a fourth dimension to AM. Intelligent materials such as piezoelectric, shape-memory, giant magnetostrictive, and nanomaterials extend the scope of applications from sensors to artificial muscles. The review discusses diverse 3D printing technologies in conjunction with intelligent materials, envisioning a future where these materials redefine additive manufacturing landscapes. AM technologies showcase their compatibility with intelligent materials and their potential to revolutionize various industries. The compatibility of intelligent materials with these technologies opens avenues for creating complex, functional, and customized objects with improved mechanical, thermal, and electrical qualities. 4D printing and the fusion of intelligent materials with bioinspired design principles offer a glimpse into the future of adaptive and functionally superior 3D-printed objects.
Corner smoothing for CNC machining of linear tool path: A review
Advanced virtual manufacturing systems: A review
A short review on milling dynamics in low-stiffness cutting conditions: Modeling and analysis
Machining process monitoring and application: a review
On-line tool wear monitoring based on machine learning
Electrochemical discharge machining for fabricating holes in conductive materials: A review
Prediction and suppression of chatter in milling of structures with low-rigidity: A review
Intelligent forming technology: State-of-the-art review and perspectives
Titanium alloy material has excellent properties such as low density, high strength, good oxidation resistance, creep resistance, etc. It has a broad application prospect in various fields. However, these characteristics also make it dif-ficult to process. Grinding is an essential method for high efficiency and precision machining of titanium alloy, ob-taining good machining precision and surface quality. The removal mechanism of titanium alloy is helpful to im-prove the surface quality of titanium alloy grinding. The recent research results in this field are reviewed. Firstly, the grinding technology types of titanium alloy were summarized, and the machining characteristics were systematically analyzed from two aspects of abrasive wear and material removal behavior of titanium alloy. Finally, the development trend of titanium alloy grinding technology in the prospect.
Machining data have been increasingly crucial with the development of modern manufacturing strategies, and the explosive growth of data amount revolutionizes how to collect and analyze data. In machining process, anomalies such as machining chatter and tool wear occur frequently, which strongly affect the process by reducing accuracy and quality as well as increasing the time and cost. As a typical type of machining data, signals acquired in real time by advanced sensor techniques are widely embraced to detect those anomalies. This paper reviews the recent development and applications of process monitoring technologies in machining processes, and typical application scenarios in machining processes are discussed with the latest literatures and current research issues. Potential future trends of process data monitoring and analysis for intelligent machining are put forward at the end of the paper.
This article presents a comprehensive review on the machining technology of aero-engine casings. The material removal mechanism of mechanical machining and nontraditional machining is introduced in the first part. Then, several mechanical machining technologies of aero-engine casings (e.g. numerical control machining, turn-milling complex machining, machining vibration suppression) are summarized. Subsequently, the research progress and academic achievements are explored in detail in terms of the electrochemical machining, electric discharging machining and ultrasonic machining in the field of nontraditional machining technology of aero-engine casings. Finally, the existing challenges in mechanical machining technology and nontraditional machining technology of aero-engine casings are analyzed, and the developing tendencies to aero-engine casings machining is proposed.
Compared with traditional additive manufacturing technology (3D printing), 4D printing technology (four-dimensional printing) increases the time dimension. The structure prepared by 4D printing process can change its shape and configuration with the external environment (i.e. light, heat, magnetism, electricity, etc.), which has a broad application prospect. This paper introduces several typical implementation methods of 4D printing in combination with the typical research results of 4D printing in recent years. The printing materials, design methods, and simulation methods of current 4D printing technology are summarized. Finally, the possible development directions of 4D printing technology and its application prospects in the fields of biomedicine, soft robotics, aerospace, etc. are introduced, and some problems of 4D printing technology are discussed.
Structured light method is one of the best methods for automated 3D measurement in industrial production due to its stability and speed. However, when the surface of industrial parts has high dynamic range (HDR) areas, e.g. rust, oil stains, or shiny surfaces, phase calculation errors may happen due to low modulation and pixel over-saturation in the image, making it difficult to obtain accurate 3D data. This paper classifies and summarizes the existing high dynamic range structured light 3D measurement technologies, compares the advantages and analyzes the future development trends. The existing methods are classified into multiple measurement fusion (MMF) and single best measurement (SBM) based on the measurement principle. Then, the advantages of the various methods in the two categories are discussed in detail, and the applicable scenarios are analyzed. Finally, the development trend of high dynamic range 3D measurement based on structed light is proposed.
The processed surface integrity of the propeller has a vital impact on the performance, efficiency, and noise of the entire power energy conversion device, and the bionic micro-structured surface is conducive to improving the noise reduction performance of the working parts. In this paper, the microstructure of the propeller blade surface is machined by precision abrasive belt grinding. Based on the surface roughness detection and 3D morphology analysis results, a univariate model of propeller surface groove with V-shaped section is established. The flow field analysis, numerical analysis of cavitation, and noise performance analysis of general marine propellers and bionic marine propellers are also carried out. The results show that the maximum noise of the propeller with the bionic grooved surface is 94.7 decibels, and the maximum noise of the general propeller is 146 decibels. The noise reduction effect is increased by 35%, which provides a new method of precision abrasive belt grinding for the noise reduction of the propeller.
The dynamic responses of milling system change the ideal trajectories of cutting teeth and therefore plays a critical role in determining the machining accuracy. The amplitude of cutting vibrations could reach tens of or even hundreds of micrometers in low-stiffness cutting conditions, for example, when milling thin-walled parts and/or using slender tools. Usually, moderate cutting parameters are utilized to avoid excessive cutting loads, strong milling chatter or large dynamic deflections, which however, significantly lowers the productivity. In spite of decades of study, it is still a challenge to accurately model, efficiently analyze, reliably monitor and precisely control the dynamic milling process in low-stiffness cutting conditions. In this paper, the recent advances and research challenges on dynamics modeling and response analysis are briefly reviewed.
The rapid development of artificial intelligence (AI) technology makes it possible for achieving intelligent forming. It will bring great breakthrough of material forming technology, realizing the unmanned watching, intelligent processing design and intelligent control during forming process. Moreover, it can greatly improve the forming accuracy, mechanical properties, forming efficiency and economic benefits, and promote the continuous emergence of new forming technology. Thus, the intelligent forming technology, integrating AI technology and advanced forming technology, has become an international research focus. This paper reviews the recent developments of intelligent forming technology from four kinds of common forming technology, i.e., intelligent casting, intelligent plastic forming, intelligent welding, and intelligent additive manufacturing. Moreover, the current research issues and future trends of intelligent forming technology are put forward at the end of the paper.
With the increasing requirements for accuracy and integrity of machining under severe application environment, electrochemical discharge machining (ECDM) has evolved continuously for fabricating micro-holes. The method can be categorized into two types based on whether the material being machined is electrically conductive or non-conductive. Most research to date has been focused on non-conductive materials, with numerous introductory review articles. However, despite a growing number of studies of machining conductive materials, there is a lack of systematic analyses and summaries. Therefore, the purpose of this paper is to fill an important gap in the literature by presenting a comprehensive review of the research and development of ECDM technology for processing conductive materials, especially micro-holes. First, the characteristics of this method are summarized. Second, the development of this method and the mechanism of discharge are compared and analyzed. Third, a discussion is given on how machining performance is affected by parameters such as solution conductivity, electrical parameters, tool electrode structure, and workpiece material. Also, to enhance the machining quality, some auxiliary ECDM measures are presented. Finally, future prospects and trends of ECDM are identified.
As an auxiliary mechanical device, Air Turbine Starter (ATS) uses compressed air as power source to start and drive the engine. It withstands the impact of high-pressure airflow during operation, which may cause collision between key components. For this reason, it is necessary to investigate the transient dynamics of ATS rotor system. However, different from the traditional dual rotor structure, ATS uses magnetic reduction gear (MRG) as a reduction unit, which involves multiple physical fields such as magnetic field and stress field, bringing challenges to transient dynamics analysis. In this paper, the magnetic interaction forces between various rotors are innovatively simplified into the form of springs, and added to the solution model to achieve the decoupling of multiple physical fields. On this basis, the transient displacement response of MRG-ATS has been analyzed using transient dynamics theory. The results indicate that the transient displacement of the rotor system has obvious characteristics of oscillation attenuation. The study reveals the feasibility of MRG-ATS application under transient shock.
