Search Results (16)

This article presents the wear characteristics of the working surface of WC-Co (Tungsten Carbide–Cobalt) tungsten carbide tools obtained using the innovative U-FAST (Upgraded Field-Assisted Sintering Technology) method for particleboard machining. Three groups of tools with a similar chemical composition but differing WC (Tungsten Carbide) grain sizes were tested. Milling tests were carried out on a CNC (Computer Numerical Control) machine tool with the following cutting parameters: spindle rotation at 15,000 rpm, a feed rate of 0.25 mm per tooth, and a feed rate of 3.75. The experimental results show that tools with submicron WC grit sizes of 0.4 µm and 0.8 µm have the longest tool life. Wear of the cutting edges occurred through the removal of the cobalt bond between the tungsten carbide grains, leading to fracture and mechanical removal of the grains from the cutting edge surface. The similarities in the relative wear characteristics of blades with submicron tungsten carbide grain sizes suggest that micro-abrasion and bond phase extrusion may be the main wear mechanisms under the experimental conditions. Nanometric WC grain size significantly influences tool wear through chipping and cracking. Full article

Silk fibroin, known for its biocompatibility and biodegradability, holds significant promise for biomedical applications, particularly in drug delivery systems. The precise fabrication of silk fibroin particles, specifically those ranging from tens of nanometres to hundreds of microns, is critical for these uses. This study introduces elliptical vibration micro-turning as a method for producing silk fibroin particles in the form of cutting chips to serve as carriers for drug delivery systems. A hybrid finite element and smoothed particle hydrodynamics (FE-SPH) model was used to investigate how vibration parameters, such as frequency and amplitude, influence chip formation and morphology. This research is essential for determining the size and shape of silk fibroin particles, which are crucial for their effectiveness in drug delivery systems. The results demonstrate the superior capability of elliptical vibration micro-turning for producing shorter, spiral-shaped chips in the size range of tens of microns, in contrast to the long, continuous chips with zig-zag folds and segmented edges generated by conventional micro-turning. The unique zig-zag shapes result from the interplay between the high flexibility and hierarchical structure of silk fibroin and the controlled cutting environment provided by the diamond tool. Additionally, higher vibration frequencies and lower vertical amplitudes promote chip curling, facilitate breakage, and improve chip control, while reducing cutting forces. Experimental trials further validate the accuracy of the hybrid model. This study represents a significant advancement in the processing of silk fibroin film, offering a complementary approach to fabricating short, spiral-shaped silk fibroin particles with a high surface-area-to-volume ratio compared to traditional spheroids, which holds great potential for enhancing drug-loading efficiency in high-precision drug delivery systems. Full article

The grain size effect is an important factor in determining the material removal behavior of polycrystalline silicon (p-Si). In the present study, to improve the understanding of nanoscale machining of p-Si, we performed molecular dynamics simulation of nanometric cutting on a p-Si workpiece and discussed the grain size effect on material removal behavior and subsurface damage formation. The simulation results indicate that when cutting on the polycrystal workpiece, the material removal process becomes unstable compared with single crystals. Higher removal efficiency, less elastic recovery and higher frictional coefficient are observed as the average grain size decreases. In the subsurface workpiece, when the grain size decreases, slip along grain boundaries merges as a nonnegligible process of the plastic deformation and suppresses the elastic deformation ahead of the cutting tool. It is also revealed that when cutting on a polycrystal workpiece with smaller grains, the average stress decreases while the workpiece temperature increases due to the impediment of heat transfer by grain boundaries. These results could provide a fundamental understanding in the material deformation mechanism of p-Si during nanoscale machining. Full article

The addition of nanostructures to polymeric materials allows for a direct interaction between polymeric chains and nanometric structures, resulting in a synergistic process through the physical (electrostatic forces) and chemical properties (bond formation) of constituents for the modification of their properties and potential cutting-edge materials. This study explores a novel in situ synthesis method for PDMS-%SiO₂ nanoparticle composites with varying crosslinking degrees (PDMS:TEOS of 15:1, 10:1, and 5:1); particle concentrations (5%, 10%, and 15%); and sol-gel catalysts (acidic and alkaline). This investigation delves into the distinct physical and chemical properties of silicon nanoparticles synthesized under acidic (SiO₂-a) and alkaline (SiO₂-b) conditions. A characterization through Raman, FT-IR, and XPS analyses confirms particle size and agglomeration differences between both the SiO₂-a and SiO₂-b particles. Similar chemical environments, with TEOS and ethanol by-products, were detected for both systems. The results on polymer composites elucidate the successful incorporation of SiO₂ nanoparticles into the PDMS matrix without altering the PDMS’s chemical structure. However, the presence of nanoparticles did affect the relative intensities of specific vibrational modes over composites from −35% to 24% (Raman) and from −14% to 59% (FT-IR). The XPS results validate the presence of Si, O, and C in all composites, with significant variations in atomic proportions (C/Si and O/Si) and Si and C component analyses through deconvolution techniques. This study demonstrates the successful in situ synthesis of PDMS-SiO₂ composites with tunable properties by controlling the sol-gel and crosslinking synthesis parameters. The findings provide valuable insights into the in situ synthesis methods of polymeric composite materials and their potential integration with polymer nanocomposite processing techniques. Full article

Ultra-high-precision single-point diamond turning (SPDT) is the state-of-the-art machining technology for the advanced manufacturing of critical components with an optical surface finish and surface roughness down to one nanometer. One of the critical factors that directly affects the quality of the diamond-cutting process is the cutting force. Increasing the cutting force can induce tool wear, increase the cutting temperature, and amplify the positioning errors of the diamond tool caused by the applied cutting force. It is important to measure the cutting force during the SPDT process to monitor the tool wear and surface defects in real time. By measuring the cutting force in different cutting conditions, the optimum cutting parameters can be determined and the best surface accuracies with minimum surface roughness can be achieved. In this study a smart cutting tool for in-process force measurement and nanopositioning of the cutting tool for compensating the displacements of the diamond tool during the cutting process is designed and analyzed. The proposed smart cutting tool can measure applied forces to the diamond tool and correct the nanometric positioning displacements of the diamond tool in three dimensions. The proposed cutting tool is wireless and can be used in hybrid and intelligent SPDT platforms to achieve the best results in terms of optical surface finish. The simulation results are shown to be almost consistent with the results of the derived analytical model. The preliminary results pave the way for promising applications of the proposed smart cutting tool in SPDT applications in the future. Full article

Tungsten carbide (WC) has the characteristics of high hardness, high strength, corrosion resistance, wear resistance and excellent fracture toughness. Accordingly, it has been commonly used as the material for cutting tools and molds in glass-forming techniques. To obtain ultra-smooth surfaces, fine polishing of WC is indispensable. However, the efficiency of WC polishing is low using the existing polishing methods, and the mechanism behind the polishing process requires further investigation. Specifically, the effect of the binder in WC polishing is not clear since there are different kinds of WC with various weight percentages of the binder. In this paper, we present the findings of a study on the polishing performance of two kinds of WC material, with and without the binder, using a semi-rigid (SR) bonnet polishing tool. A series of experiments were performed on a 6-DOF robotic polishing instrument to investigate the material-removal characteristics, surface integrity and sub-surface damage after polishing. The results demonstrate that the SR bonnet polishing tool successfully reduced the surface roughness of WC with and without the binder to the nanometric level, though the lowest surface roughness was obtained on binder-less WC. No obvious sub-surface damage was observed under SEM inspection, while the processing efficiency was greatly improved owing to the high material removal rate of the tool. Based on our analysis of key polishing parameters and corresponding surface integrities, the effect of the binder on the polishing performance is explained, which offers excellent guidance for WC polishing. Full article

In the present work, Ni-10 wt.%TiO₂ self-lubricating composite sinters were prepared via a powder metallurgy. Commercially available powder of nickel and non-commercial nanometric titanium dioxide (approx. 30 nm size) produced by the microwave method was used. The produced sinters were characterized by evenly distributed TiO₂ particles in a nickel matrix and a hardness of approx. 110 HV5. Pin-on-disc wear tests at room temperature and 600 °C were carried out. Light Microscopy (LM), Scanning Electron Microscopy (SEM), Energy Dispersive Spectroscopy (EDS), and X-Ray Diffraction (XRD) were used to characterize the wear mechanism of sintered materials. The coefficient of friction of the Ni-10 wt.% TiO₂—Inconel^®625 friction pair tested at room temperature was approx. 0.52. At the test temperature of 600 °C, the same friction pair had a friction coefficient of 0.35. The main wear mechanisms in dry friction conditions at 23 °C were cutting and ploughing. At the test temperature of 600 °C, formation of tribofilm on the surfaces of the friction pair was observed, which reduces the wear by friction. Full article

In this study, nanoporous gold (NPG) was synthesized by free corrosion dealloying of an amorphous precursor, Au₂₀Cu₄₈Ag₇Pd₅Si₂₀ (at. %), in a mixture of nitric and hydrofluoric acid, starting from amorphous melt-spun ribbons. NPG revealed a 3D nanoporous structure composed of pores and multigrain ligaments of an average size of 60 nm. NPG was further anodized in oxalic acid at 8 V vs. Ag/AgCl reference electrode to obtain a bimodal morphology composed of ligaments disrupted in finer features. Both NPG and anodized samples (A-NPG) were found to be mechanically stable to bending and active for surface-enhanced Raman scattering (SERS). SERS activity of samples was investigated using 4,4′-bipyridine as a probe molecule. A detection limit of 10⁻¹⁶ M was found for both samples, but in A-NPG, the signal was strongly enhanced. The extremely high enhancement obtained for A-NPG is attributed both to the small size of ligaments and crystals of which they are made, as well as to the nanometric features resulting from anodization treatment. Such a microstructure showed homogenous SERS response in terms of average enhancement all across the surface, as demonstrated by mapping measurements. Furthermore, NPG and A-NPG were tested as electrodes for electrocatalytic applications, showing good properties. The engineering steps from the amorphous precursor to A-NPG led us to obtain a high-sensing platform, with extremely low detection limit and intrinsic properties, that might significantly contribute to the cutting-edge technology of the future. Full article

As a typical third-generation semiconductor material, silicon carbide (SiC) has been increasingly used in recent years. However, the outstanding performance of SiC component can only be obtained when it has a high-quality surface and low-damage subsurface. Due to the hard–brittle property of SiC, it remains a challenge to investigate the ductile machining mechanism, especially at the nano scale. In this study, a three-dimensional molecular dynamics (MD) simulation model of nanometric cutting on monocrystalline 3C-SiC was established based on the ABOP Tersoff potential. Multi-group MD simulations were performed to study the removal mechanism of SiC at the nano scale. The effects of both cutting speed and undeformed cutting thickness on the material removal mechanism were considered. The ductile machining mechanism, cutting force, hydrostatic pressure, and tool wear was analyzed in depth. It was determined that the chip formation was dominated by the extrusion action rather than the shear theory during the nanocutting process. The performance and service life of the diamond tool can be effectively improved by properly increasing the cutting speed and reducing the undeformed cutting thickness. Additionally, the nanometric cutting at a higher cutting speed was able to improve the material removal rate but reduced the quality of machined surface and enlarged the subsurface damage of SiC. It is believed that the results can promote the level of ultraprecision machining technology. Full article

Polycrystalline cubic boron nitride (PcBN) are super-hard materials with high hardness and excellent abrasive resistance, widely used in cutting tools for precision machining of automotive and aerospace parts; however, their brittle properties make them prone to premature failure. Coatings are often applied to PcBN to extend their range of applicability and durability. Conventional coating methods are limited to the thickness range of a few hundred nanometres, poor adhesion to the substrate, and limited stability under ambient conditions. To further the properties of PcBN composites, in this paper, we explore the use of ultrasonic bonding to apply thick coatings (30–80 μm) on PcBN cutting tools. For the first time, a multi-walled carbon nanotube (MWCNT) powder is preplaced on a PcBN substrate to allow an unconventional coating technique to take place. The effects of ultrasonic bonding parameters on the change of mechanical properties of the coated tools are investigated through scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDX), micro-hardness analyses, and white light interferometry. The structure of the carbon nanotubes is investigated through transmission electron microscopy (pre coating) and cross-section of the bonded MWCNTs is studied via focused ion beam milling and SEM to evaluate the bonding between the multi-walled nanotubes. Optimum processing windows (i.e., bonding speed, energy, and pressure) are discovered for coating MWCNTs on PcBN. Focus ion beam milling analyses revealed a relationship between consolidation parameters and porosity of MW(pCNT) bonds. The proposed method paves the way for the novel design of functional coatings with attunable properties (i.e., thickness and hardness) and therefore improved productivity in the machining of aerospace and automotive parts. Full article

In dimensional metrology it is necessary to carry out multi-axis angle and displacement measurement for high-precision positioning. Although the state-of-the-art linear displacement sensors have sub-nanometric measurement resolution, it is not easy to suppress the increase of measurement uncertainty when being applied for multi-axis angle and displacement measurement due to the Abbe errors and the influences of sensor misalignment. In this review article, the state-of-the-art multi-axis optical sensors, such as the three-axis autocollimator, the three-axis planar encoder, and the six-degree-of-freedom planar encoder based on a planar scale grating are introduced. With the employment of grating reflectors, measurement of multi-axis translational and angular displacement can be carried out while employing a single laser beam. Fabrication methods of a large-area planar scale grating based on a single-point diamond cutting with the fast tool servo technique and the interference lithography are also presented, followed by the description of the evaluation method of the large-area planar scale grating based on the Fizeau interferometer. Full article

In this work, the distribution and evolution of micro-defect in single crystal γ-TiAl alloy during nanometer cutting is studied by means of molecular dynamics simulation. Nanometer cutting is performed along two typical crystal directions: $\left[\overline{1}00\right]$ and $\left[\overline{1}01\right]$ . A machined surface, system potential energy, amorphous layer, lattice deformation and the formation mechanism of chip are discussed. The results indicate that the intrinsic stacking fault, dislocation loop and atomic cluster are generated below the machined surface along the cutting crystal directions. In particular, the Stacking Fault Tetrahedron (SFT) is generated inside the workpiece when the cutting crystal direction is along $\left[\overline{1}00\right]$ . However, a “V”-shape dislocation loop is formed in the workpiece along $\left[\overline{1}01\right]$ . Furthermore, atomic distribution of the machined surface indicates that the surface quality along $\left[\overline{1}00\right]$ is better than that along $\left[\overline{1}01\right]$ . In a certain range, the thickness of the amorphous layer increases gradually with the rise of cutting force during nanometric cutting process. Full article

The surface generation mechanism of the Cu alloys in ultra-precision diamond turning is investigated by both simulation and experimental methods, where the effects of the cutting parameters on the surface characteristics are explored, including the workpiece spindle speed, the cutting depth, the feed rate and the nose radius of the diamond tool. To verify the built model, the cutting experiments are conducted at selected parameters, where the causes of the error between the simulation and the machining results are analyzed, including the effects of the materials microstructure and the diamond tool wear. In addition, the nanometric surface characteristics of the Cu alloys after the diamond turning are identified, including the finer scratching grooves caused by the tool wear, the formation of the surface burs and the adhesion of graphite. The results show that the built model can be basically used to predict the surface topography for the selection of the appropriate machining parameters in the ultra-precision diamond turning process. Full article

Compound sinusoidal grid surface with nanometric finish plays a significant role in modern systems and precision calibrator, which can make the systems smaller, the system structure more simple, reduce the cost, and promote the performance of the systems, but it is difficult to design and fabricate by traditional methods. In this paper, a compound freeform surface constructed by a paraboloidal base surface and sinusoidal grid feature surface is designed and machined by slow tool servo (STS) assisted with single point diamond turning (SPDT). A novel combination of the constant angle and constant arc-length method is presented to optimize the cutting tool path. The machining error prediction model is analyzed for fabricating the compound sinusoidal grid surface. A compound sinusoidal grid surface with 0.03 mm amplitude and period of 4 is designed and cutting process is simulated by use of MATLAB software, machining experiment is done on ultra-precision machine tool, the surface profile and topography are measured by Taylor Hobson and Keyence VR-3200, respectively. After dealing with the measurement data of compound freeform surface, form accuracy 4.25 μm in Peak Village value (PV), and surface roughness 89 nm in Ra are obtained for the machined surface. From the theoretical analysis and experimental results, it can be seen that the proposed method is a reasonable choice for fabricating the compound sinusoidal grid surface. Full article

Currently, nanotechnology represents an important tool and an efficient option for extending the shelf life of foods. Reducing particle size to nanometric scale gives materials distinct and improved properties compared to larger systems. For food applications, this technology allows the incorporation of hydrophilic and lipophilic substances with antimicrobial and antioxidant properties that can be released during storage periods to increase the shelf life of diverse products, including whole and fresh-cut fruits and vegetables, nuts, seeds, and cheese, among others. Edible coatings are usually prepared with natural polymers that are non-toxic, economical, and readily available. Nanosystems, in contrast, may also be prepared with biodegradable synthetic polymers, and liquid and solid lipids at room temperature. In this review, recent developments in the use of such nanosystems as nanoparticles, nanotubes, nanocomposites, and nanoemulsions, are discussed critically. The use of polymers as the support matrix for nanodispersions to form edible coatings for food preservation is also analyzed, but the central purpose of the article is to describe available information on nanosystems and their use in different food substrates to help formulators in their work. Full article