Search Results (180)

The machining of Ti-6Al-4V thin-walled parts is characterized by high cutting temperatures, significant force fluctuations, and complex thermomechanical coupling. Cryogenic Minimum Quantity Lubrication Technology (CMQL) uses bio-lubricant as the lubrication carrier, combined with the cooling characteristics of cryogenic temperature medium, showing good cooling and lubrication performance and environmental friendliness. However, the cooling and lubrication mechanism of different cryogenic media in synergy with bio-lubricants is still unclear. This paper establishes convective heat transfer coefficient and penetration models for cryogenic media in the cutting zone, based on the jet core theory and the continuum medium assumption. The model results show that cryogenic air has a higher heat transfer coefficient, while cryogenic CO₂ exhibits a better penetration ability in the cutting zone. Further milling experiments show that compared with cryogenic air, the average temperature rise, average cutting force and surface roughness of workpiece surface with cryogenic CO₂ as cryogenic medium are reduced by 23.6%, 32.8%, and 11.8%, respectively. It is considered that excellent permeability is the key to realize efficient cooling and lubrication in the cutting zone by Cryogenic CO₂ Minimum Quantity Lubrication Technology. This study provides a theoretical basis and technical reference for efficient precision machining of titanium alloy thin-walled parts. Full article

The multi-passage lubrication system is adopted to meet the demand of the main heat generation parts (gears and bearings) in the three-stage planetary transmission system of a large tracked vehicle. As rotational speed increases, the flow regime inside the passages with multi-oil outlets becomes highly complex. Under high-speed conditions, the flow rate in Zone 2 decreases sharply, and some oil outlets even drop to zero, representing a 100% reduction amplitude, which results in an unstable oil supply for heat generation parts and even potential lubrication cut-off. In the present work, the lubrication characteristics of the oil supply system for the three-stage planetary transmission system are investigated by a combination of CFD (computational fluid dynamics) simulations and experiments. A complete CFD model of the multi-passage lubrication system is established, comprising a stationary oil passage, a main oil passage, and a three-stage variable-speed oil passage. A transient calculation method based on sliding mesh rotation domain control is used to simulate the oil-filling process in the oil passages, and the oil supply characteristics of the variable-speed oil passage are investigated. A test bench for the multi-stage planetary transmission system is designed and constructed to collect oil flow data from outlets of planetary gear sets. The comparison between simulated and experimental results confirms the validity of the proposed numerical method. Additionally, numerical simulations are conducted to investigate the effects of key factors, including input speed, oil supply pressure, and oil temperature, on the oil flow rate of outlets. The results indicate that the rotational speed is the major parameter affecting the oil flow rate at the oil passage outlets. This work provides a practical guidance for optimizing lubrication design in complex multi-stage planetary transmission systems. Full article

High temperatures generated during machining can lead to undesirable outcomes such as surface deterioration, subsurface damage, tool wear, and shortened tool life. Effective heat removal from the cutting zone is therefore essential for maintaining process stability and part quality. Conventional cooling systems typically apply a constant amount of cutting fluid without considering the actual temperature in the cutting zone, which may result in unnecessary coolant use and inefficient temperature control. This study introduces an innovative machining approach that integrates machine learning techniques to estimate the optimal lubrication interval and maintain the desired cutting temperature. The proposed system dynamically adjusts coolant application based on real-time temperature data and machining parameters, preventing excessive or insufficient cooling. Comparative analyses show that the new system reduces coolant consumption by 22.5 mL per minute compared with conventional cooling and by 2.5 mL per minute compared with minimum quantity lubrication (MQL). This improvement corresponds to an annual reduction of approximately 12.3 T of CO₂e emissions. The results demonstrate that the developed system enables machining at the optimum temperature, enhancing tool life, surface quality, and energy efficiency while significantly lowering environmental and health impacts associated with cutting fluids. The integration of machine learning also supports automated decision-making in smart manufacturing environments, reducing operator dependency and contributing to sustainable and economically efficient production. Full article

Ti–6Al–4V (TC4) dual-phase titanium alloy is widely used in aerospace components owing to its excellent strength-to-weight ratio and high-temperature stability. However, conventional machining often generates a wide heat-affected zone (HAZ) and oxide or recast layers, which deteriorate the microstructure and reduce long-term reliability. In this study, the water-jet-guided laser (WJGL) process was applied to investigate how coupled laser–water interactions influence the groove morphology, elemental distribution, and crystallographic evolution of TC4 alloy. Under optimized parameters, the WJGL process reduced the HAZ width to less than 1 $\mathsf{\mu }$m, effectively removed the resolidified layer, and suppressed surface oxidation. SEM, EDS, and EBSD analyses confirmed that the $\alpha$ + $\beta$ dual-phase structure remained stable, with no significant phase transformation or grain coarsening. Compared with conventional laser cutting, WJGL achieved smoother surfaces, improved interfacial integrity, and reduced thermal damage. These findings highlight the potential of WJGL for precision machining of high-performance titanium alloys and provide theoretical and experimental support for enhancing the microstructural control and service reliability of aerospace TC4 components. Full article

Achieving optimal lubrication during machining processes, particularly turning of stainless steel, remains a significant challenge due to dynamic variations in cutting conditions that affect tool life, surface quality, and environmental impact. Conventional Minimum Quantity Lubrication (MQL) systems provide fixed flow rates and often fail to adapt to changing process parameters, limiting their effectiveness under fluctuating thermal and mechanical loads. To address these limitations, this study proposes an ambient-aware adaptive Auto-Tuned MQL (ATM) system that intelligently controls both nanofluid concentration and lubricant flow rate in real time. The system employs embedded sensors to monitor cutting zone temperature, surface roughness, and ambient conditions, linked through a feedback-driven control algorithm designed to optimize lubrication delivery dynamically. A Taguchi L9 design was used for experimental validation on AISI 304 stainless steel turning, investigating feed rate, cutting speed, and nanofluid concentration. Results demonstrate that the ATM system substantially improves machining outcomes, reducing surface roughness by more than 50% and cutting force by approximately 20% compared to conventional MQL. Regression models achieved high predictive accuracy, with R-squared values exceeding 99%, and surface analyses confirmed reduced adhesion and wear under adaptive lubrication. The proposed system offers a robust approach to enhancing machining performance and sustainability through intelligent, real-time lubrication control. Full article

One of the key measures of cutting tool efficiency in machining processes is tool wear. In recent decades, numerical modeling of this phenomenon—primarily through finite element cutting models—has gained increasing importance. A crucial requirement for the reliable application of such models is the selection of an appropriate friction model, which strongly affects the accuracy of wear predictions. However, choosing the friction model type and its parameters remains a nontrivial challenge. This paper examines the effect of different friction model types and their parameters on the Archard and Usui wear model indicators, as well as on the main cutting process characteristics: cutting force components, temperature in the primary cutting zone, contact length between the tool rake face and the chip, shear angle, and chip compression ratio. To evaluate their impact on predicted tool wear—expressed qualitatively through the wear indicators of the aforementioned models—several widely used friction models implemented in commercial FEM software were applied: the shear friction model, Coulomb friction model, hybrid friction model, and constant tau model. The simulated values of these cutting process characteristics were then compared with experimental results. Full article

The Erdaoling Mining area, located in Inner Mongolia, NW China, is recognized for its considerable potential in coalbed methane (CBM) exploration and development. However, the complex structures in this region have significant influences on coal reservoir characteristics, particularly pore structure features. This study focuses on the No. 2 coal seam of the Middle Jurassic Yan’an Formation. Three structural patterns were classified based on the existing structural characteristics of the study area. Coal samples of No. 2 coal seam were collected from different structural positions, and were subjected to low-temperature CO₂ adsorption (LTCO₂A), low-temperature N₂ adsorption/desorption (LTN₂A), low-field nuclear magnetic resonance (LF-NMR), and scanning electron microscopy (SEM) experiments, so that the structural controlling effects on pore structure would be revealed. Quantitative analysis results indicate that in terms of asymmetric syncline, from the limb to the core, the total porosity and movable fluid porosity of the coal decreased by 1.47% and 0.31%, respectively, reaching their lowest values at the core. Meanwhile, the dominant pore type shifted from primarily one-end closed pores to “ink-bottle” pores, indicating increased pore complexity. In the fold-thrust structure, the micropore specific surface area, micropore volume, mesopore specific surface area, mesopore volume, and total porosity show clear correlations with variations in coal seam structure. These parameters all reach their maximum values in the fault-cut zone at the center of the syncline, measuring 268.26 m²/g, 0.082 cm³/g, 0.601 m²/g, 1.262 cm³/g, and 4.2%, respectively. Simple pore types, like gas pores and vesicular pores, were identified in the syncline limbs, while open pores, “ink-bottle” pores, and complex multiporous types were mainly developed at fault locations, indicating that faults significantly increase the complexity of coal reservoir pore types. For the broad and gentle syncline and small-scale reverse fault combination, porosity exhibits a decreasing trend from the syncline limbs toward the core. Specifically, the mesopore specific surface area and movable fluid porosity increased by 52.24% and 43.69%, respectively, though no significant effect on micropores was observed. The syncline core in this structural setting developed normal gas pore clusters and tissue pores, with no occurrence of highly complex or heterogeneous pore types, indicating that neither the broad gentle syncline nor the small-scale faulting significantly altered the pore morphology. Comparatively, the broad and gentle syncline and small-scale reverse fault combination was determined to exert the strongest modification on pore structures of coal reservoir, followed by the asymmetric syncline, while the broad syncline alone demonstrated minimal influence. Full article

Grain shape is a critical determinant of rice yield, quality, and market value. Recent advances in molecular biology, genomics, and systems biology have revealed a complex regulatory network governing grain development, integrating genetic loci, plant hormone signaling, transcriptional regulation, protein ubiquitination, epigenetic modifications, and environmental cues. This review summarizes key genetic components such as QTLs, transcription factors, and hormone pathways—including auxin, cytokinin, gibberellin, brassinosteroids, and abscisic acid—that influence seed size through regulation of cell division, expansion, and nutrient allocation. The roles of the ubiquitin–proteasome system, miRNAs, lncRNAs, and chromatin remodeling are also discussed, highlighting their importance in fine-tuning grain development. Furthermore, we examine environmental factors that impact grain filling and size, including temperature, light, and nutrient availability. We also explore cutting-edge breeding strategies such as gene editing, functional marker development, and wild germplasm utilization, along with the integration of multi-omics platforms like RiceAtlas to enable intelligent and ecological zone-specific precision breeding. Finally, challenges such as pleiotropy and non-additive gene interactions are discussed, and future directions are proposed to enhance grain shape improvement for yield stability and food security. Full article

During machining, most of the mechanical energy is converted into heat. A substantial part of this heat is transferred to the cutting tool, causing a rapid rise in tool temperature. Excessive thermal loads accelerate tool wear and lead to displacement of the tool center point, reducing machining accuracy and workpiece quality. This challenge is particularly pronounced when machining titanium alloys. Due to their low thermal conductivity, titanium alloys impose significantly higher thermal loads on the cutting tool compared to conventional carbon steels, making the process more difficult. To reduce temperatures in the cutting zone, cutting fluids are widely employed in titanium machining. They have been shown to significantly extend tool life. Cutting fluids are broadly categorized into cutting oils and water-based cutting fluids. Owing to their distinct thermophysical properties, these fluids exhibit notably different cooling and lubrication performance. However, current research lacks comprehensive cross-comparative studies of different cutting fluid types, which hinders the selection of optimal cutting fluids for process optimization. This study examines the influence of three cutting fluids—emulsion, cutting oil, and synthetic oil-free fluid—on tool wear, temperature, surface quality, and energy consumption during flood-cooled end milling of Ti-6Al-4V. A novel experimental setup incorporating embedded thermocouples enabled real-time temperature measurement near the cutting edge. Tool wear, torque, and surface roughness were recorded over defined feed lengths. Among the tested fluids, emulsion achieved the best balance of cooling and lubrication, resulting in the longest tool life with a feed travel path of 12.21 m. This corresponds to an increase of approximately 200% compared to cutting oil and oil-free fluid. Cutting oil offered superior lubrication but limited cooling capacity, resulting in localized thermal damage and edge chipping. Water-based cutting fluids reduced tool temperatures by over 300 °C compared to dry cutting but, in some cases, increased notch wear due to higher mechanical stress at the entry point. Power consumption analysis revealed that the cutting fluid supply system accounted for 60–70% of total energy use, particularly with high-viscosity fluids like cutting oil. Complementary thermal and CFD simulations were used to quantify heat partitioning and convective cooling efficiency. The results showed that water-based fluids achieved heat transfer coefficients up to 175 kW/m²·K, more than ten times higher than those of cutting oil. These findings emphasize the importance of selecting suitable cutting fluids and optimizing their supply to enhance tool performance and energy efficiency in Ti-6Al-4V machining. Full article

Titanium alloys (Ti-6Al-4V) are widely used in the aerospace field. However, as a typical difficult-to-machine material, titanium alloys have a low thermal conductivity, a high chemical activity, and a significant adiabatic shear effect. In conventional milling (CM), the temperature in the cutting zone rises sharply, leading to tool adhesion, rapid wear, and damage to the workpiece surface. This article systematically investigated the influence of process parameters on the surface roughness, cutting force, and cutting temperature in the ultrasonic-vibration-assisted milling (UAM) process of titanium alloys, based on which multi-objective optimization process of the milling process parameters was conducted, by utilizing the grey relational analysis method. An orthogonal experiment with four factors and four levels was conducted. The effects of various process parameters on the surface roughness, cutting force, and cutting temperature were systematically analyzed for both UAM and CM. The grey relational analysis method was employed to transform the optimization problem of multiple process target parameters into a single-objective grey relational degree optimization problem. The optimized parameter combination was as follows: an ultrasonic amplitude of 6 μm, a spindle speed of 6000 rpm, a cutting depth of 0.20 mm, and a feed rate of 200 mm/min. The experimental results indicated that the surface roughness Sa was 0.268 μm, the cutting temperature was 255.39 °C, the cutting force in the X direction (FX) was 5.2 N, the cutting force in the Y direction (FY) was 7.9 N, and the cutting force in the Z direction (FZ) was 6.4 N. The optimization scheme significantly improved the machining quality and reduced both the cutting forces and the cutting temperature. Full article

This study aimed to evaluate and optimize the effects of three auxin types—indole-3-butyric acid (IBA), naphthaleneacetic acid (NAA), and indole-3-acetic acid (IAA)—applied at four concentrations (1000, 3000, 5000, and 8000 ppm) on the rooting performance of Photinia × fraseri Dress. stem cuttings. The experiment was conducted under controlled greenhouse conditions using a sterile perlite medium. Rooting trays were placed on bottom-heated propagation benches maintained at a set temperature of 25 ± 2 °C to stimulate root formation. However, the actual rooting medium temperature—measured manually every four days from the perlite zone using a calibrated thermometer—ranged between 18 °C and 22 °C, with an overall average of approximately 20 ± 2 °C. The average values of these root-zone temperatures were used in the statistical analyses. Rooting percentage, root number, root length, callus formation, and mortality rate were recorded after 120 days. In addition to classical one-way ANOVA, response surface methodology (RSM) was employed to model and optimize the interactions between auxin type, concentration, and temperature. The results revealed that 5000 ppm IBA significantly enhanced rooting performance, yielding the highest rooting percentage (85%), average root number (5.80), and root length (6.30 cm). RSM-based regression models demonstrated strong predictive power, with the model for rooting percentage explaining up to 92.79% of the total variance. Temperature and auxin concentration were identified as the most influential linear factors, while second-order and interaction terms—particularly T·ppm—contributed substantially to root length variation. These findings validate IBA as the most effective exogenous auxin for the vegetative propagation of Photinia × fraseri Dress. and provide practical recommendations for optimizing hormone treatments. Moreover, the study offers a robust statistical modeling framework that can be applied to similar propagation systems in woody ornamental plants. Full article

High-strength steel has high strength and low thermal conductivity, and its thin-walled parts are very susceptible to residual stress and deformation caused by cutting heat during the drilling process, which affects the machining accuracy and quality. High-strength steel thin-walled components are widely used in aerospace and other high-end sectors; however, systematic investigations into their temperature fields during drilling remain scarce, particularly regarding the evolution characteristics of the temperature field in thin-wall drilling and the quantitative relationship between drilling parameters and these temperature variations. This paper takes the thin-walled parts of AF1410 high-strength steel as the research object, designs a special fixture, and applies infrared thermography to measure the bottom surface temperature in the thin-walled drilling process in real time; this is carried out in order to study the characteristics of the temperature field during the thin-walled drilling process of high-strength steel, as well as the influence of the drilling dosage on the temperature field of the bottom surface. The experimental findings are as follows: in the process of thin-wall drilling of high-strength steel, the temperature field of the bottom surface of the workpiece shows an obvious temperature gradient distribution; before the formation of the drill cap, the highest temperature of the bottom surface of the workpiece is distributed in the central circular area corresponding to the extrusion of the transverse edge during the drilling process, and the highest temperature of the bottom surface can be approximated as the temperature of the extrusion friction zone between the top edge of the drill and the workpiece when the top edge of the drill bit drills to a position close to the bottom surface of the workpiece and increases with the increase in the drilling speed and the feed volume; during the process of drilling, the highest temperature of the bottom surface of the workpiece is approximated as the temperature of the top edge of the drill bit and the workpiece. The maximum temperature of the bottom surface of the workpiece in the drilling process increases nearly linearly with the drilling of the drill, and the slope of the maximum temperature increases nearly linearly with the increase in the drilling speed and feed, in which the influence of the feed on the slope of the maximum temperature increases is larger than that of the drilling speed. Full article

Manufacturing in modern industrial sectors involves the machining of components where the undeformed chip thickness inevitably decreases to values comparable to the tool edge radius. Under such conditions, the ploughing effect between the workpiece and the tool becomes dominant, followed by the noticeable formation of a stagnation zone. This paper presents research focused on the analysis of the cutting process for small cross-sections of the removed layers, based on cutting force components. This study investigated the machining of two titanium alloy grades—Ti Grade 5 (Ti-6Al-4V) and Ti Grade 2—with the main focus on process stability. A material separation model was analyzed to demonstrate the mechanism of material flow within the cross-section of the machined layer. It was found that the material has a limited ability to flow sideways at the boundary of the chip thickness, thus determining the probable size of the stagnation zone in front of the cutting edge. Orthogonal cutting experiments enabled the determination of the minimum chip thickness coefficient for constant temperature conditions, independent of the tool edge radius, as $h_{min0}=$0.313. In oblique cutting tests, the sensitivity of thin-layer machining was demonstrated for the determined values of minimum undeformed chip thickness. By applying the 0–1 test for chaos, the measurement time (parameter $T·dt$) was determined for both titanium alloys to determine the range of observable chaotic behavior. The analyses confirmed that Ti Grade 2 enters chaotic dynamics much more rapidly than Ti Grade 5 and displays local cutting instabilities independent of the uncut chip thickness. Full article

When processing widely used materials in welded structures such as steels, a surface operation such as plasma cutting applied in the automated Computer Numerical Control (CNC) version can provide technical and economic benefits to the cut components, but the impact on health and environment must be addressed accordingly. In this paper, a plate with a base material made of S355J2 + AR structural steel is cut in 10 pieces with plasma in a water-bed designed and manufactured by the authors in order to mitigate such risks. The surfaces cut in the water-bed are compared to surfaces cut in open air by macroscopic analyses of the edge cut, by microscopic analyses of the cut parts—base material, heat-affected zone, and cut area—and by hardness determinations. The results reveal improvements as a result of plasma cutting in the water-bed: slag reduction, preservation of granulation, transformations in the austenitic temperature zone, and hardness in the heat-affected zone. Compared to a classical cutting procedure such as oxygen flame cutting, the proposed procedure offers a clean alternative and also requires low maintenance. Full article

Nickel-based superalloy Hastelloy C276 is widely used in high-performance industries due to its strength, corrosion resistance, and thermal stability. However, these same properties pose substantial challenges in machining, resulting in high tool wear, surface defects, and dimensional inaccuracies. This study investigates methods to enhance machining performance and surface quality by evaluating the tribological behavior of TiSiN/TiAlN-coated carbide inserts under six cooling and lubrication conditions: dry, MQL with coconut oil, Cryo-LN₂, Cryo-LCO₂, MQL–Cryo-LN₂, and MQL–Cryo-LCO₂. Open-slot finishing was performed at constant cutting parameters, and key indicators such as cutting zone temperature, tool wear, surface roughness, chip morphology, and microhardness were analyzed. The hybrid MQL–Cryo-LN₂ approach significantly outperformed other methods, reducing cutting zone temperature, tool wear, and surface roughness by 116.4%, 94.34%, and 76.11%, respectively, compared to dry machining. SEM and EDS analyses confirmed abrasive, oxidative, and adhesive wear as the dominant mechanisms. The MQL–Cryo-LN₂ strategy also lowered microhardness, in contrast to a 39.7% increase observed under dry conditions. These findings highlight the superior performance of hybrid MQL–Cryo-LN₂ in improving machinability, offering a promising solution for precision-driven applications. Full article