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Micromachines
Special Issues
Hybrid Energy Field Manufacturing Technology for Difficult-to-Machine Materials
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Hybrid Energy Field Manufacturing Technology for Difficult-to-Machine Materials

A special issue of Micromachines (ISSN 2072-666X). This special issue belongs to the section "D：Materials and Processing".

Deadline for manuscript submissions: 30 June 2025 | Viewed by 4513

Special Issue Editors

Dr. Zhen Zhang

E-Mail Website
Guest Editor
School of Aerospace Engineering, Huazhong University of Science and Technology, Wuhan 430074, China
Interests: precision machining of composite materials; laser processing; glass molding; process optimization
Special Issues, Collections and Topics in MDPI journals
Dr. Zhi Chen

E-Mail Website
Guest Editor
State Key Laboratory of Precision Manufacturing for Extreme Service Performance, College of Mechanical and Electrical Engineering, Central South University, Changsha 410083, China
Interests: EDM; WEDM; laser machining; engineering ceramic; high temperature alloy; multi energy field composite machining
Prof. Dr. Jun Ma

E-Mail Website
Guest Editor
Mechanical and Electrical Engineering Institute, Zhengzhou University of Light Industry, Zhengzhou 450002, China
Interests: green manufacturing; networked collaborative manufacturing; EDM; WEDM; AI
Dr. Wuyi Ming

E-Mail Website
Guest Editor
Mechanical and Electrical Engineering Institute, Zhengzhou University of Light Industry, Zhengzhou 450002, China
Interests: manufacturing process; mechanics machining; CNC machining; mechanical properties; electrical discharge machining; micro EDM mechanical processes; CNC programming; mechanical behavior of materials
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Difficult-to-machine materials such as high-temperature alloys and other high-strength and ductile materials, ceramics, hard and brittle glass materials, and composite materials with both high hardness and high toughness are widely used in aerospace, marine equipment, intelligent terminals, biomedical and other fields. However, their low damage and efficient processing have always been common challenges. Hybrid-energy-field machining technology provides new ideas for solving the above problems. In recent years, scholars have attempted various emerging technologies around hybrid-energy-field composite machining, including laser-induced plasma machining, magnetic field assisted electrical machining, laser-assisted cutting machining, ultrasound-assisted hot-pressing forming, and other composite special energy field manufacturing technologies. The purpose of this Special Issue is to showcase the new technological achievements and research progress in the field of hybrid-energy-field composite manufacturing, promote the coordinated development of relevant disciplines, and summarize and promote the processing science problems, physical and chemical mechanisms, key technologies, and promotion applications in the process of hybrid-energy-field composite manufacturing, which has significant theoretical and practical significance.

We look forward to receiving your submissions!

Dr. Zhen Zhang
Dr. Zhi Chen
Prof. Dr. Jun Ma
Dr. Wuyi Ming
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Micromachines is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2100 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • difficult-to-machine materials
  • precision manufacturing
  • electric discharge
  • laser-induced plasma machining
  • magnetic field composite electrical machining
  • laser-assisted cutting machining
  • ultrasonic-assisted-hot-pressing forming
  • composite special energy field manufacturing technologies

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Published Papers (4 papers)

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Research

17 pages, 10646 KiB  
Article
The Influence of Microsecond Pulsed Electric Field and Direct Current Electric Field on the Orientation Angle of Boron Nitride Nanosheets and the Thermal Conductivity of Epoxy Resin Composites
by Yan Mi, Yiqin Peng, Wentao Liu, Lei Deng and Benxiang Shu
Micromachines 2025, 16(4), 413; https://doi.org/10.3390/mi16040413 - 30 Mar 2025
Viewed by 228
Abstract
The electric field orientation method effectively promotes the orientation and arrangement of BN nanosheets, forming a thermal conduction network and enhancing the thermal conductivity of the composite material. In this study, microsecond pulsed electric field and direct current electric field were applied to [...] Read more.
The electric field orientation method effectively promotes the orientation and arrangement of BN nanosheets, forming a thermal conduction network and enhancing the thermal conductivity of the composite material. In this study, microsecond pulsed electric field and direct current electric field were applied to induce the orientation and arrangement of BN nanosheets and improve the thermal conductivity of epoxy resin composites. Under a microsecond pulsed electric field of 50 Hz, 1.5 μs, and 8 kV/mm, the average orientation angle of BN nanosheets increased by 147.7%, and the thermal conductivity of the composite reached 0.352 W/(m·K), which is 1.84 times that of pure epoxy resin. In contrast, under a DC electric field of 70 V/mm, the average orientation angle of BN nanosheets increased by only 57.9%, while the thermal conductivity of the composite reached 0.364 W/(m·K), 1.91 times that of pure epoxy resin. The results indicate that the microsecond pulsed electric field primarily enhances the local orientation of the fillers to improve thermal conductivity, whereas the DC electric field mainly enhances the global arrangement of the fillers to achieve a similar effect. Additionally, thermogravimetric analysis and differential scanning calorimetry were conducted to evaluate the thermal properties of the composites. The results demonstrate that after BN nanosheets orientation and arrangement within the epoxy resin induced by both microsecond pulsed and DC electric fields, the composites exhibited a higher glass transition temperature and improved thermal stability. This study systematically explores the effects of microsecond pulsed and DC electric fields on filler orientation and arrangement, providing valuable insights for the fabrication of electric field-oriented composites. Full article
(This article belongs to the Special Issue Hybrid Energy Field Manufacturing Technology for Difficult-to-Machine Materials)
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26 pages, 62591 KiB  
Article
Thermal Bending Simulation and Experimental Study of 3D Ultra-Thin Glass Components for Smartwatches
by Shunchang Hu, Peiyan Sun, Zhen Zhang, Guojun Zhang and Wuyi Ming
Micromachines 2024, 15(10), 1264; https://doi.org/10.3390/mi15101264 - 17 Oct 2024
Viewed by 1358
Abstract
The heating system is an essential component of the glass molding process. It is responsible for heating the glass to an appropriate temperature, allowing it to soften and be easily molded. However, the energy consumption of the heating system becomes particularly significant in [...] Read more.
The heating system is an essential component of the glass molding process. It is responsible for heating the glass to an appropriate temperature, allowing it to soften and be easily molded. However, the energy consumption of the heating system becomes particularly significant in large-scale production. This study utilized G-11 glass for the simulation analysis and developed a finite element model for the thermal conduction of a 3D ultra-thin glass molding system, as well as a thermal bending model for smartwatches. Using finite element software, the heat transfer between the mold and the glass was modeled, and the temperature distribution and thermal stress under various processing conditions were predicted. The findings of the simulation, when subjected to a numerical analysis, showed that heating rate techniques significantly affect energy consumption. This study devised a total of four heating strategies. Upon comparison, optimizing with heating strategy 4, which applies an initial heating rate of 35 mJ/(mm2·s) during the initial phase (0 to 60 s) and subsequently escalates to 45 mJ/(mm2·s) during the second phase (60 to 160 s), resulted in a reduction of 4.396% in the system’s thermal output and a notable decrease of 7.875% in the heating duration, respectively. Furthermore, a single-factor research method was employed to study the forming process parameters. By comparing the numerical simulation results, it was found that within the temperature range of 615–625 °C, a molding pressure of 25–35 MPa, a heating rate of 1.5–2.5 °C/s, a cooling rate of 0.5–1 °C/s, and a pulse pressure of 45–55 Hz, the influence on residual stress and shape deviation in the glass was minimal. The relative error range was within the 20% acceptable limit, according to the experimental validation, which offered crucial direction and ideas for process development. Full article
(This article belongs to the Special Issue Hybrid Energy Field Manufacturing Technology for Difficult-to-Machine Materials)
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17 pages, 14444 KiB  
Article
Precision Electrochemical Micro-Machining of Molybdenum in Neutral Salt Solution Based on Electrochemical Analysis
by Yuqi Wu, Guoqian Wang, Moucun Yang and Yan Zhang
Micromachines 2024, 15(10), 1191; https://doi.org/10.3390/mi15101191 - 26 Sep 2024
Cited by 2 | Viewed by 984
Abstract
Molybdenum is an important material in modern industry, widely used in extreme environments such as rocket engine nozzles and microelectrodes due to its high melting point, excellent mechanical properties, and thermal conductivity. However, as a difficult-to-machine metal, traditional machining methods struggle to achieve [...] Read more.
Molybdenum is an important material in modern industry, widely used in extreme environments such as rocket engine nozzles and microelectrodes due to its high melting point, excellent mechanical properties, and thermal conductivity. However, as a difficult-to-machine metal, traditional machining methods struggle to achieve the desired microstructures in molybdenum. Electrochemical machining (ECM) offers unique advantages in manufacturing fine structures from hard-to-machine metals. Studies have shown that molybdenum exhibits a fast corrosion rate in alkaline or acidic solutions, posing significant environmental pressure. Therefore, this study investigates the electrochemical machining of molybdenum in neutral salt solutions to achieve high-precision microstructure fabrication. First, the polarization curves and electrochemical impedance spectroscopy (EIS) of molybdenum in NaNO3 solutions of varying concentrations were measured to determine its electrochemical reaction characteristics. The results demonstrate that molybdenum exhibits good electrochemical reactivity in NaNO3 solutions, leading to favorable surface erosion morphology. Subsequently, a mask electrochemical machining technique was employed to fabricate arrayed microstructures on the molybdenum surface. To minimize interference between factors, an orthogonal experiment was used to optimize the parameter combination, determining the optimal machining process parameters. Under these optimal conditions, an array of micro-groove structures was successfully fabricated with an average groove width of 110 μm, a depth-to-width ratio of 0.21, an aspect ratio of 9000, and a groove width error of less than 5 μm. Full article
(This article belongs to the Special Issue Hybrid Energy Field Manufacturing Technology for Difficult-to-Machine Materials)
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13 pages, 1422 KiB  
Article
Influence of Anode Immersion Speed on Current and Power in Plasma Electrolytic Polishing
by Joško Valentinčič, Henning Zeidler, Toni Böttger and Marko Jerman
Micromachines 2024, 15(6), 783; https://doi.org/10.3390/mi15060783 - 14 Jun 2024
Cited by 1 | Viewed by 1239
Abstract
Plasma electrolytic polishing (PeP) is mainly used to improve the surface quality and thus the performance of electrically conductive parts. It is usually used as an anodic process, i.e., the workpiece is positively charged. However, the process is susceptible to high current peaks [...] Read more.
Plasma electrolytic polishing (PeP) is mainly used to improve the surface quality and thus the performance of electrically conductive parts. It is usually used as an anodic process, i.e., the workpiece is positively charged. However, the process is susceptible to high current peaks during the formation of the vapour–gaseous envelope, especially when polishing workpieces with a large surface area. In this study, the influence of the anode immersion speed on the current peaks and the average power during the initialisation of the PeP process is investigated for an anode the size of a microreactor mould insert. Through systematic experimentation and analysis, this work provides insights into the control of the initialisation process by modulating the anode immersion speed. The results clarify the relationship between immersion speed, peak current, and average power and provide a novel approach to improve process efficiency in PeP. The highest peak current and average power occur when the electrolyte splashes over the top of the anode and not, as expected, when the anode touches the electrolyte. By immersion of the anode while the voltage is applied to the anode and counterelectrode, the reduction of both parameters is over 80%. Full article
(This article belongs to the Special Issue Hybrid Energy Field Manufacturing Technology for Difficult-to-Machine Materials)
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