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2022 Vol. 65, No. 8 Published: 2022-04-15

FEATURE FORUM RESEARCH C0NTENTS COVER STORY

COVER STORY

	1	COVER


		2022 Vol. 65 (8): 1-1 [Abstract] ( 134 ) HTML^New PDF (1630 KB) ( 205 )

C0NTENTS

	6	CONTENTS


		2022 Vol. 65 (8): 6-10 [Abstract] ( 88 ) HTML^New PDF (407 KB) ( 35 )

FEATURE

	14	Study on Longitudinal-Bending Hybrid Ultrasonic Vibration Milling Device and Machining Performance of TC4 Titanium Alloy
		ZHANG Junjie，LIU Yingxiang，HU Wangjie，DU Pengfei，HAN La，DENG Jie，QIU Xu，ZHAO Xuesen，HU Zhenjiang，SUN Tao
		DOI: 10.16080/j.issn1671-833x.2022.08.014
		TC4 titanium alloy has been widely used in aviation and aerospace industry because of its excellent comprehensive mechanical properties. However, the high plasticity and low thermal conductivity of TC4 lead to pronounced tool-chip adhesion, which is a key factor restricting the improvement of its milling performance. In this paper, a longitudinal-bending hybrid ultrasonic vibration assisted milling method is proposed to improve the milling performance of TC4, through the reduction of tool-chip adhesion accompanied by the controllable intermittent cutting realized by individually controlling the amplitude and phase of longitudinal and bending ultrasonic vibration of the cutting tool. Firstly, the kinematics principle of longitudinal-bending hybrid ultrasonic vibration assisted milling is analyzed theoretically. Based on this, the longitudinal-bending hybrid ultrasonic vibration tool is designed and manufactured. After assembly of the vibration tool with the high-speed spindle, the radial runout of the milling tool is less than 20μm. Then, a three-axis linkage equipment of longitudinal-bending hybrid ultrasonic vibration assisted milling is established, with which the vibration-assisted milling experiments of TC4 are carried out, and the experimental results are characterized and analyzed. The experimental results show that the applying of longitudinal-bending hybrid ultrasonic vibration to conventional milling effectively reduces the cutting force, the burr generation and the tool wear, while improving the surface machining quality, which demonstrate the feasibility of applying the longitudinal-bending hybrid ultrasonic vibration assisted milling in improving the milling performance of TC4 titanium alloy.
		2022 Vol. 65 (8): 14-21 [Abstract] ( 288 ) HTML^New PDF (29252 KB) ( 135 )

COVER STORY

	22	Development of High-Speed Wave-Motion Ultrasonic Machining Technology With High Efficiency and Low Damage
		ZHANG Deyuan, PENG Zhenlong, GENG Daxi, JIANG Xinggang, LIU Yihang, ZHOU Zehua, YIN Xiaoming
		DOI: 10.16080/j.issn1671-833x.2022.08.022
		In the field of aviation manufacturing, high-efficiency and low-damage processing of difficult-to-machine materials such as superalloys, titanium alloys and composites has always been the bottleneck restricting the industry production capacity. With the continuous upgrading of China’s manufacturing technology, frontier technologies such as intelligence, advanced numerical control, advanced cutting tools and advanced cooling have been widely used in the processing of difficult-to-machine materials. However, the traditional continuous cutting mode still fails to make a substantive breakthrough in cutting linear speed of difficult-to-machine alloy, which limits further improvement of its production capacity. In recent years, high-speed wave-motion ultrasonic machining technology has emerged. This technology upgrades the traditional continuous cutting mode to high-speed separate cutting mode, which not only breaks the machining speed limit of traditional vibration cutting technology, but also realizes the high-speed machining of difficult-to-machine alloy materials and greatly improves its machining accuracy, surface integrity and machining efficiency. Based on a brief overview of background and basic principle of high-speed wave-motion ultrasonic machining, this paper focuses on the process principle, process effect and application of high-speed wave-motion ultrasonic machining technology in turning, milling and hole drilling. The process adaptability optimization and application advantages of high-speed wave-motion ultrasonic machining technology are also prospected in this paper.
		2022 Vol. 65 (8): 22-33 [Abstract] ( 393 ) HTML^New PDF (21882 KB) ( 251 )

FORUM

	36	Research Progress on Ultrasonic Assisted Friction Stir Welding of Aluminum Alloy
		SHI Lei，XIAO Yichen，WU Chuansong，SU Hao，LIU Xiaochao，GAO Song
		DOI: 10.16080/j.issn1671-833x.2022.08.036
		Guide::null
		Ultrasonic assisted friction stir welding (UaFSW) is a novel variation of conventional friction stir welding (FSW), which utilizing the external ultrasonic vibration energy to improve the inherent disadvantages of conventional friction stir welding. This article reviews the progress status on ultrasonic assisted friction stir welding of aluminum alloy, including the methods to superimposing ultrasonic vibration energy in FSW, the effects of superimposing ultrasonic vibration energy on the microstructural evolution and mechanical properties of the joints, and the mechanism of superimposing ultrasonic energy in FSW. It shows that UaFSW can reduce the welding loads, improve the joint formation, suppress the weld defects, increase the welding speed, and enhance the joint properties. Multi-physical numerical simulation of UaFSW process shows that all the thermal effect, acoustoplastic effect and friction reduction effect lead to a several difference in thermal processes and plastic material flow comparing with conventional FSW, which resulting in an improved joint formation and mechanical properties as state above. Finally, the challenges and future research topics are emphasized systematically.
		2022 Vol. 65 (8): 36-46 [Abstract] ( 257 ) HTML^New PDF (28446 KB) ( 351 )

	47	Process Optimization for Ultrasonic-Assisted Magnetic Abrasive Finishing of Titanium Alloy
		MA Fujian, PU Bin, LIU Xin, LUO Qichao
		DOI: 10.16080/j.issn1671-833x.2022.08.047
		In order to study the influence of machining parameters on ultrasonic-assisted magnetic abrasive finishing (UAMAF) of titanium alloy, the orthogonal experiments were carried out with surface roughness and material removal rate (MRR) as evaluating indicator. The single-objective and multi-objective optimization of the machining parameters were carried out based on signal-to-noise ratio (S/N) and grey correlation analysis methods. The results show that the best process aiming at surface roughness and MRR is the abrasive particle size of 50/60#, amplitude of 14μm, and tool speed of 1000r/min and 1200r/min, magnetic pole and workpiece gap of 1mm and 1.25mm, finishing time of 40min and 30min respectively. The optimized surface roughness and MRR are R a 0.08μm and 30.5mg/h respectively. The optimum process combining surface roughness and MRR is the abrasive particle size of 50/60#, amplitude 14μm, finishing time of 30min, magnetic pole and workpiece gap of 1.00mm, tool speed of 1200r/min. The surface roughness and MRR are R a 0.12μm and 27.9mg/h respectively.
		2022 Vol. 65 (8): 47-52 [Abstract] ( 155 ) HTML^New PDF (12986 KB) ( 95 )

	53	Research Progress on Ultrasonic Vibration-Assisted EDM Micro-Hole Machining
		YIN Zhen，ZHANG Peng，YU Daguo，SHEN Xingquan，MIAO Qing，DAI Chenwei，ZHANG Kun，LI Hua
		DOI: 10.16080/j.issn1671-833x.2022.08.053
		Ultrasonic vibration assisted electrical discharge (UVE), as a special composite machining technology, is one of the effective methods to improve the micro-holes machining performance of difficult-to-cut materials. In UVE micro-holes processing, according to the different forms of ultrasonic vibration, it can be divided into three modes: electrode vibration, workpiece vibration and dielectric vibration. In the UVE micro-hole processing of electrode vibration, the ultrasonic frequency is generally 20–40kHz, and the ultrasonic amplitude is about 5μm, which can improve the material removal rate by 40%–60%, and can machine the micro-hole with an aspect ratio of up to 30. In the UVE micro-hole processing of workpiece vibration, the ultrasonic frequency is mostly less than 30kHz and the ultrasonic amplitude is less than 10μm, and the material removal rate can be increased by about 40% and the micro-hole taper reduced by about 30%. In the UVE micro-hole processing of working fluid vibration, the ultrasonic frequency is generally greater than 40kHz, and the ultrasonic amplitude is greater than 5μm, which can increase the material removal rate by up to 33 times, and the hole wall roughness can reach R a 0.2μm. The research result of the three types of UVE micro-hole processing are summarized and analyzed, the three types of UVE micro-hole processing mechanisms and existing problems are discussed, and the characteristics and scope of application of the three types of UVE micro-hole processing are compared, and the development trends of UVE micro-hole processing were prospected.
		2022 Vol. 65 (8): 53-63 [Abstract] ( 240 ) HTML^New PDF (8839 KB) ( 102 )

	64	Elliptic Ultrasonic Assisted Fixed-Abrasive Polishing of AlN Ceramics
		LI Gengzhuo, WU Yongbo, WANG Qiang
		DOI: 10.16080/j.issn1671-833x.2022.08.064
		AlN ceramics are considered as the most ideal substrate material for high integration and high-power devices packaging due to its high thermal conductivity, low thermal expansion coefficient and good mechanical strength, and have great prospects for application in automotive chips, aerospace and defense military. However, as the primary methods of the substrate planarization, lapping and polishing of AlN ceramics are encountering the bottleneck of low processing efficiency caused by the employment of loose abrasive slurries. In addition, the chemicals in abrasive slurries can cause increased environmental expenses. In this research, for the purpose of solving environmental problems and improving the polishing efficiency of AlN ceramics, a vitrified-bonded abrasive pellet containing fine abrasives is employed to realize the fixed-abrasive dry polishing. With this method, higher material removal rate can be obtained, but the chip cannot be discharged in time during the dry machining, which will lead to the deterioration of surface integrity. Consequently, an elliptic ultrasonic vibration is applied to the abrasive pellet during the dry polishing. It is found from experiments that the elliptic ultrasonic vibration has a catalytic effect on the chip emission, which is more favourable for better surface quality and higher material removal rate.
		2022 Vol. 65 (8): 64-68/75 [Abstract] ( 187 ) HTML^New PDF (1422 KB) ( 615 )

	69	Experimental Study on Tangential Ultrasonic-Assisted Mirror Grinding of Zirconia Ceramics
		QIAO Jiaping，WANG Qiang，WU Hanqiang，ZENG Jiang，WU Yongbo
		DOI: 10.16080/j.issn1671-833x.2022.08.069
		Zirconia ceramics are difficult-to-machine materials and their application are restricted as a result of the difficulty in precision machining due to their high brittleness and low fracture toughness. Against this problem, a tangential ultrasonic-assisted mirror grinding method was proposed. The effect of ultrasonic amplitude on the work-surface roughness, the grinding force and temperature, and the wear condition of grinding wheel with/without ultrasonic were studied. The results demonstrated that the mirror surface was successfully obtained on the zirconia ceramics workpiece by tangential ultrasonic-assisted grinding, and the work-surface roughness decreased by 43.8% to R_a19.9nm at ultrasonic amplitude A_p–p=4.66μm, compared with conventional grinding (A_p–p=0). The normal grinding force decreased with the increase of ultrasonic amplitude, with the maximum decrease of 34%, but the rate gradually slowed down. The change trend of grinding temperature was similar with that of grinding force, showing the temperature at A_p–p=4.66μm was lower than that without ultrasonic by 34.5%. In addition, the wear condition of grinding wheel was improved, reducing the falling off abrasive grains and extending the life of grinding wheel with ultrasonic.
		2022 Vol. 65 (8): 69-75 [Abstract] ( 152 ) HTML^New PDF (12702 KB) ( 86 )

RESEARCH

	76	Experimental Study on Laser Assisted Cluster Magnetorheological Polishing of Sapphire Substrate
		LAI Keming, YAN Qiusheng, XIE Xiaozhu, PENG Qingfa, ZHAO Peng
		DOI: 10.16080/j.issn1671-833x.2022.08.076
		In order to achieve the purpose of high efficiency and high quality ultra-smooth and flat processing of sapphire substrate, a new process of pre-treatment and modification of sapphire wafer surface material by femtosecond laser and then cluster magnetorheological polishing is proposed in this paper. The effects of femtosecond laser scanning speed and cluster magnetorheological polishing time on the material removal rate and surface roughness of laser pretreated sapphire wafer were studied. At the same time, the material properties of sapphire surface before and after femtosecond laser treatment were analyzed by means of X-ray photoelectron spectroscopy (XPS) and X-ray diffraction (XRD), and the mechanism of femtosecond laser-assisted cluster magnetorheological polishing was studied. The results show that femtosecond laser pretreatment has a significant effect on cluster magnetorheological polishing of sapphire wafers. The material removal rate of cluster magnetorheological polishing of sapphire wafers pretreated with femtosecond laser is more than doubled, and when the scanning speed of femtosecond laser is 100mm/s, better surface roughness and surface morphology of sapphire can be obtained after polishing. The results of XPS and XRD show that there is no chemical reaction on the surface of sapphire substrate irradiated by femtosecond laser, but the amorphization and microcrystallization of the crystal structure of sapphire surface layer caused by femtosecond laser are beneficial to the material removal in the process of cluster magnetorheological polishing. It is concluded that femtosecond laser can microcrystallize and amorphize the surface layer of sapphire, which is beneficial to improve the polishing efficiency and surface performance of cluster magnetorheological polishing sapphire.
		2022 Vol. 65 (8): 76-83 [Abstract] ( 130 ) HTML^New PDF (26793 KB) ( 71 )

	84	Research Status of 7xxx Aluminum Alloy Extrusion Technology and Equipment
		YUAN Hang，LU Zheng，SUN Gang，LI Guoai，GAO Wenli
		DOI: 10.16080/j.issn1671-833x.2022.08.084
		Lightweight aluminum alloy materials have become the most widely used non-ferrous metal materials in society. Taking 7xxx series aluminum alloy as the research object, which introduced the application direction of its profile produced by extrusion. The main factors affecting extrusion processing are analyzed, and taking electromagnetic stirring technology, as an example, to produce the large-scale casting. That listed the construction and ability of large-scale hydraulic extruder in the world, described the mold manufacturing process from CAD/CAE/CAM software design to CNC machining center, and compared the characteristics of forward extrusion, backward and other processes , the improvement measures of hydraulic system and isothermal processing are given. Last, the effect of extrusion times on the microstructure and properties of the materials was observed, which provides a reference for the extrusion processing.
		2022 Vol. 65 (8): 84-92/106 [Abstract] ( 193 ) HTML^New PDF (1458 KB) ( 1892 )

	93	Research on Flexible Turnover Tooling With Automatic Dis-Placement System for Whole Aircraft
		WANG Zhenwen，FAN Di,ZHAO Rong，GUO Longjiang
		DOI: 10.16080/j.issn1671-833x.2022.08.093
		In order to meet the needs of riveting and gluing in the whole aircraft manufacturing process, the whole aircraft needs to be turned over. The traditional turnover tooling has the disadvantages of poor turning accuracy, low automation of control system and low reusability. Therefore, a kind of flexible turnover tooling is developed for whole aircraft based on the turning process. The tooling uses split gantry structure, universal fixed joint and automatic displacement control system to realize 360° flexible turnover of the whole aircraft. The tooling can adapt to different sizes of aircraft products by adjusting the position of split gantry. The transition tooling and universal fixed joint are used to realize the flexible clamping of the whole aircraft on the turnover device. The automatic position control system is used for the turning positioning of the tooling to ensure the turning accuracy and reliability of the whole aircraft. Tooling can complete the whole aircraft assembly work of different types. Compared with the traditional tooling, the tooling can effectively reduce the tooling manufacturing cost, improve the turnover accuracy, open operation space and versatility of tooling.
		2022 Vol. 65 (8): 93-97 [Abstract] ( 186 ) HTML^New PDF (6796 KB) ( 517 )

	98	Parameter Optimization of Creep Feed Grinding for IC10 Directionally Solidified Superalloy
		YANG Zhongxue，ZHANG Shuaiqi，WANG Sai，WANG Shuai，ZHANG Changchun，XIONG Yifeng，JIANG Ruisong，ZHANG Qiang
		DOI: 10.16080/j.issn1671-833x.2022.08.098
		Orthogonal experiments were designed to research the effects of grinding parameters and surface roughness on the fatigue life of IC10 superalloy during creep feed grinding. Based on experimental results, empirical models of grinding parameters and surface roughness, fatigue life were established. Then multi-objective optimization of grinding parameters was carried out for smaller surface roughness, longer fatigue life and higher machining efficiency. The results show that the fatigue life increases with increasing grinding wheel speed while it decreases with increasing workpiece feed speed or grinding depth. The wheel speed has the highest influence on the fatigue life, followed by workpiece feed speed and grinding depth. As surface roughness R a increased from 0.44μm to 0.94μm, the fatigue life decreased about 87.1% from 9.69×10⁶ to 1.25×10⁶, indicating that the grinding surface roughness has a significant influence on fatigue life. By optimization of grinding parameters, a group of suitable grinding parameters could be given as: wheel speed v_s = 20m/s, the workpiece feed speed v_w = 117mm/min, and the grinding depth a_p =0.48mm, with taking, full account of the fatigue life, machining efficiency and surface roughness.
		2022 Vol. 65 (8): 98-106 [Abstract] ( 216 ) HTML^New PDF (5116 KB) ( 412 )

	107	Preliminary Stage of Preparation Technology and Parameters of Flexible Thin-Film Sensor
		DONG Yiyi, ZHONG Hongjie
		DOI: 10.16080/j.issn1671–833x.2022.08.107
		Flexible thin film sensors for arrays high frequency heat flux fluctuating signals have promising future in wind tunnel testing. With excellent mechanical properties, chemical stability and high temperature resistance, polyimide is one of the ideal substrate materials for micro fabrication of thin film sensors. However, due to the hydrophobic group on the surface of the material, the prepared metal coating is easy to be destroyed, limiting the applications. In this paper, plasma surface treatment is used to improve the hydrophilicity of the polyimide thin film in the preparation of flexible thin film sensor, The bonding force with the metal material is improved. With the characteristics of UV photoresist denaturation, the design sensor pattern is transferred to the film through the combination of uniform photoresist and photoresist technology. Then the required metal layer is physically deposited by a magnetron sputtering coater to realize the fabrication of micro-nano patterned thin film sensors, the optimum parameters of sputtering power and time are determined by qualitative study of the key process of magnetron sputtering.
		2022 Vol. 65 (8): 107-112 [Abstract] ( 148 ) HTML^New PDF (6658 KB) ( 804 )

	113	Study on Fatigue Crack Propagation Characteristics of Electron Beam Welded Joint of 30CrMnSiNi2A Steel
		ZHANG Yingyun，HU Shengshuang，ZHU Zenghui，ZHENG Chao，LONG Jian，ZHANG Linjie
		DOI: 10.16080/j.issn1671-833x.2022.08.113
		This paper compared the fatigue crack growth rate of the base metal (BM), heat affect zone (HAZ) and weld metal (WM) of the ultra-high strength steel electron beam welded joint of 26mm thick 30CrMnSiNi2A. The experimental results showed that the fatigue crack growth resistance of the BM was the best; HAZ was relatively weak; WM was closed to that of the BM. The fractured morphologies of BM, HAZ and WM fatigue samples were observed. It was found that multi-source crack initiation was found in each region of the joint, fatigue striations were found in the stable and fast crack propagation area, and a large number of dimples were found in fractured zone of the three regions of the joint, presented ductile fracture characteristics. The microstructure characteristics of the three regions of the joint were observed by optical microscope and scanning electron microscope. It was found that the differences between the microstructure of each region of the joint were slightly, and all of them were tempered martensite.
		2022 Vol. 65 (8): 113-118 [Abstract] ( 180 ) HTML^New PDF (15222 KB) ( 139 )

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