The machining accuracy control of honing 9310 steel thin-walled components (e.g., helicopter tail drive shafts) remains challenging owing to complex abrasive-workpiece interactions. This paper proposes a modeling approach that integrates abrasive machining theory with kinematic analysis. A novel honing-stone machining simulation model was developed based on the abrasive machining theory, enabling the accurate prediction of key parameters, including the number of effective abrasive grains, depth of cut, and tangential force under varying normal forces. By incorporating the honing stone trajectories, a diameter increment distribution model was established, achieving a prediction error of 9.74

Geometric deviations in near-net-shape (NNS) parts often lead to the undercut defects and demanding numerical control (NC) programming, posing challenges for high-precision machining. To address these issues, this paper proposes a Gaussian mixture model (GMM)-driven non-rigid toolpath morphing framework integrating a novel skeleton-skin strategy. First, a design intent-preserving model is developed to construct feasible machining points (skeleton points) under nonlinear constraints of machining allowance and profile tolerance, addressing undercut regions with negative machining allowance. Second, the nominal toolpath cutter locations (skin points) are morphed to conform to the skeleton points through a GMM-based non-rigid morphing algorithm, bypassing conventional point-curve-surface reconstruction and enabling direct NC programming. Importantly, a Bayesian optimization method utilizing symmetric Hausdorff distance is introduced to determine the optimal parameters for non-rigid morphing. A comprehensive case study on a 3D-printed turbine blade, including the performance evaluations and milling experiments, is conducted to validate the proposed framework. Results show that the machined areas meet the +/- 0.10 mm profile tolerance requirement, while toolpath generation time is reduced by 31%. This work establishes a critical link between non-rigid shape compensation and efficient NC programming for NNS parts.

Due to low thermal conductivity and high specific strength, nickel-based superalloys are prone to service performance degradation caused by thermal damage during traditional high-efficiency grinding processes. Although the heat pipe grinding wheel with minimum quantity lubrication (HPGW-MQL) technology can reduce the probability of thermal damage to a certain extent, further breakthroughs are still needed. Therefore, this study proposes a new integrated process of ultrasonic vibration-assisted grinding by heat pipe grinding wheel with minimum quantity lubrication (UVAG-HPGW-MQL), aiming to balance the requirements of green grinding and the optimization of grinding performance for nickel-based superalloys. However, the mechanism of action of ultrasonic vibration on the cooling and lubrication performance of the proposed process remains unclear. Given that, comparative experiments between UVAG-HPGW-MQL and HPGW-MQL were conducted, focusing on exploring the influence of ultrasonic vibration on their cooling and lubrication performance. The experimental results, obtained when the grinding speed, workpiece feed rate, and grinding depth were set at 15–35 m/s, 40–120 mm/min, and 0.05–0.25 mm, respectively, indicate that, compared with HPGW-MQL, ultrasonic vibration causes periodic “contact-separation” between grains and workpiece. This dynamic process shortens the contact length between grains and workpiece, leading to maximum reductions of 43.85%, 22.15%, 34.16%, and 30.77% in grinding force, grinding force ratio, grinding temperature, and specific grinding energy, respectively. On the other hand, the ultrasonic cavitation effect causes atomization of the lubricating oil film adsorbed on the workpiece surface, leading to a decrease in lubrication performance and resulting in a maximum increase of 27.27% in the friction coefficient. This study provides new theoretical support and technical approaches for the green grinding of nickel-based superalloys.

Precision grinding of K417G superalloy, a key material for hot-end components of aero-engines, is plagued by large grinding forces and excessive heat generation. Clarifying the material removal mechanism is a prerequisite for optimizing the grinding process. Although single-grit grinding is a critical method for revealing this mechanism, it suffers from bottlenecks, such as the difficult acquisition of force or stress fields and poor process visualization. Finite element simulation, an alternative approach, cannot be practically applied because of the lack of dynamic mechanical properties data and a suitable constitutive model for K417G. This study systematically investigates the dynamic mechanical behavior of K417G and develops a Johnson-Cook constitutive model with high fitting accuracy. After embedding this model into single-grit grinding simulations, the study further quantifies the effects of undeformed chip thickness and grinding speed on material removal behavior. The results show that the undeformed chip thickness significantly affects the grinding force, chip morphology, and residual stress. This study not only provides a reliable constitutive basis for the simulation modeling of the precision grinding of K417G but also offers key theoretical support for the accurate optimization of grinding processes for aero-engine hot-end components, which has important engineering application value.

When milling structural components with varying axial depths and widths, cutting forces tend to fluctuate, negatively impacting tool life and machining accuracy. To mitigate the force fluctuations and enhance tool longevity, developing a simple, reliable, and easy-to-implement force control system for milling is essential, which is an important step toward advancing intelligent manufacturing. This paper explores the use of genetic algorithms (GA) for powerful optimization capabilities in developing self-tuning milling force controllers. A comprehensive framework for optimizing a fuzzy logic controller using an enhanced GA is specifically designed for the milling process. The optimization integrates the GA with a simulation model, fine-tuning membership functions and optimizing fuzzy rule selection. The enhanced GA incorporates the Integral of Time-weighted Absolute Error (ITAE) as the fitness criterion to improve the robustness and responsiveness of the controller. The optimized fuzzy logic controller is implemented within a computer numerical control system, adjusting feed rates in real-time to control milling forces. The performance of the proposed controller is validated through step and slope milling tests, demonstrating an average control accuracy of 95.52%. Comparative evaluations with other controllers show that the proposed system offers a significant improvement, achieving up to 4.58% better control accuracy in step milling tests.

Symmetrical radial-rotating thermosyphons (SLTs) have been investigated as a means to enhance heat transfer during grinding, thereby preventing workpiece burns and improving overall process efficiency. These LTs feature channels with a uniform diameter, yet previous research has shown significant limitations under conditions of high centrifugal acceleration, which negatively impacts their heat transfer capability. Specifically, SLTs with uniform diameter channels experience flow stratification due to high centrifugal forces, causing a reduction in oscillatory motion and leading to reduced heat transfer efficiency. To address such limitations, a novel 3D asymmetric loop thermosyphon (ALT) with two different channel diameters is proposed. This asymmetric configuration induces an additional pressure difference, which appears to counteract the adverse effects of centrifugal forces, thereby sustaining oscillatory motion and enhancing heat transfer especially at higher rotational speeds. The thermal performance of the ALT is evaluated in terms of thermal resistance, temperature uniformity, and heat dissipation efficiency under a wide range of centrifugal accelerations and heat fluxes. Compared to SLT, at accelerations of 18g, 73.5g, and 165g, the novel ALT demonstrates a reduction in thermal resistance of 31 %, 43 %, and 44 %, respectively. The temperature uniformity is also improved compared to SLT by 37 %. Results also showed that the ALT works as an Oscillating Heat Pipe when the acceleration remains under 1.12g. These results indicate that the ALT effectively improves heat transfer performance by maintaining oscillatory motion and enhancing temperature uniformity, ultimately offering superior adaptability for highspeed grinding applications, ensuring more stable thermal management, reducing workpiece burns, and minimizing grinding wheel wear.

Tool anomalies in computer numerical control (CNC) milling processes are unpredictable, hindering the promotion of fully automated machining. Traditional detection systems often struggle with stability due to the irregular and non-parametric nature of signals generated during dynamic milling. This study proposes an improved probability and statistics-based model for constructing tool anomaly thresholds in the time domain, with the decision-making strategy seamlessly integrated into CNC milling systems. A robust data acquisition and preprocessing framework was developed to improve the accuracy and reliability of real-time monitoring data. A Gaussian process model was employed to construct an anomaly detection threshold data set from irregular signals. Anomalies were identified when monitoring indicators surpassed the established threshold. The proposed method was validated through milling experiments of a turbine blisk, demonstrating an overall anomaly detection accuracy of 91.45%, which exceeds those of four other typical anomaly detection methods. These results confirm the effectiveness of the proposed method and its potential applicability in industry.

The excess heat generated during drilling may lead to thermal damage in tissues, necessitating the exploration of innovative methods to effectively control drilling heat. To address the issue of drilling heat and associated thermal damage control in cortical bone drilling processes, the current study proposes the implementation of oscillating heat pipes for efficient thermal management during bone drilling. In this paper, a novel oscillating heat pipe drill (OHPD) was meticulously designed to explore its strength calibration under diverse rotational speeds, drilling forces, and torques. Furthermore, the study comprehensively investigated the heat transfer mechanism and the thermal management performance of the drill at different input heat flux and rotational speeds. The results demonstrate that the OHPD efficiently transfers heat from the cortical bone. Additionally, it significantly reduces the domain of osteonecrosis, decreasing the diameter from 12.23 mm to 11.28 mm at the rotational speed of 2500 r/min. Moreover, the oscillating heat pipe drill is simulated at different speeds and heat flux. when the input heat flux ranged from 4000 to 20000 W/m2, the domain of osteonecrosis was further minimized from 11.908 mm to 11.527 mm at heat flux of 20000 W/m2. Besides, the domain of osteonecrosis was disappeared under 8000 W/m2 as OHPD was applied. Finally, Bone drilling experiments with the oscillating heat pipe drill is conducted, validating its enhanced heat transfer effect in cortical bone drilling compared to the drill. This analytical approach provides valuable insights to optimize and maximize the efficiency of the OHPD during bone drilling procedures.

The near-net-shape blanks of aero engine blades pose significant machining challenges due to their complex geometries and shape variations. Precise localization of the blank is crucial for optimizing the machining allowance. Traditional methods often fail to ensure the final machining surfaces are fully enveloped by the blank, leading to undercutting or overcutting. This study introduces an adaptive registration framework to address these issues. Firstly, a robust search algorithm based on curvature feature constraints is proposed to extract four segmentation points that divide the blade cross-section curve into the convex and concave sides, leading and trailing edges. Discrete points are generated on the above four parts to represent the cross-section curve data. Then, three registration models considering machining allowance and tolerance constraints of different regions are established to find the optimal position for the final machining surfaces step-by-step. Finally, The method is validated using a rotor turbine blade, reducing out-of-tolerance regions from 32.43% to 4.43%, demonstrating its effectiveness in localization and machining allowance optimization for near-net-shape blades.

Honing force is one of the key output variables to evaluate the machining performance of the honing process. However, the measurement of honing force during small-bore honing is difficult. The research on and modeling of honing force can help analyze the mechanism of material removal in the honing process, control the material removal rate, and improve the shape accuracy of the workpiece hole after honing. Recent research on the modeling of single-stone honing tools does not reflect reality well. In this study, a model to predict the honing force of a force-controlled, single-stone honing tool is built. The model is established through a mechanical analysis of the honing tool. This study is the first to propose that the initial shape of the workpiece bore considerably affects honing force due to the self-locking effect of honing tool. The model is verified by experiments, and the honing force predicted by the model fits the measured honing force well. The model can applied to different sizes of single- or multi-stone tools with the same working principle and therefore has a wide range of applicability. It can guide the selection of honing parameters. Moreover, it can help build a more realistic-fitting model for the prediction of the material removal distribution and is crucial to improving the shape accuracy of the bore.

As critical aero-engine components, closed impellers demand precision manufacturing to ensure reliability under extreme conditions. Traditional casting and powder-bed additive manufacturing face challenges in defect control and cost-effectiveness. Wire-arc directed energy deposition offers high material utilization and deposition rates for near-net-shape fabrication, yet its inherent high heat input induces microstructural defects such as Laves phase segregation in Inconel-718 superalloy. This study investigates CMT +P-based wire-arc DED processing of Inconel-718, focusing on energy density effects spanning 360-540 J/mm on thin-wall geometry, microstructure, and mechanical properties. Energy-dispersive X-ray spectroscopy and XRD analysis reveal that increased energy density expands primary dendrite arm spacing from 4.68 to 18.97 mu m and Laves phase area fraction from 3.12 to 8.10 %, correlating with reduced as-deposited tensile strength of 725 +/- 45 MPa. Post-deposition solution-aging heat treatment enhances ultimate tensile strength to 1354 +/- 54 MPa. The mechanical properties of Inconel-718 deposited via CMT + P were compared with those produced by the conventional CMT process. Mechanical property benchmarking against Inconel-718 casting and forging standards provides actionable insights for industrial process optimization.

Oscillating Heat Pipes (OHPs) are passive, wickless two-phase thermal devices which can be integrated into Ultrasonic Machining Systems (UMS) to stabilize operating temperatures, prevent performance degradation due to excessive heat, and improve both system stability and machining outcomes. Ultrasonic vibrations influence the heat transfer characteristics of OHPs, but the effects are not yet fully understood. This paper experimentally examines how an ultrasonic field affects the thermal performance of OHPs, focusing on temperature distribution and flow pattern changes to understand the heat transfer mechanisms. The study shows that the ultrasonic field can enhance the heat transfer coefficient of OHPs by almost 20%. This enhancement decreases as the operating temperature rises, with the greatest improvement at 70 degrees C. Further analysis reveals that ultrasonic field promotes a periodic steady-state operation inside the OHPs and characteristic periodic temperature signals. Additionally, ultrasonic cavitation enhances bubble formation and the phase change heat transfer within the OHPs, facilitating the development of flow pattern and promoting unidirectional circulation, both of which improve heat transfer. By integrating OHPs into UMS, operating temperatures can be better stabilized, leading to enhanced vibration stability in the UMS and improved surface quality of the workpiece.

Form grinding is a high-efficiency machining technology for products as fir-tree blade slots. The excessive heat generated in the grinding contact zone is the key issue for form grinding. In this paper, a profile rotating heat pipe grinding wheel (PRHP-GW) was proposed to help dissipate the grinding heat; nanofluids were applied to enhance its thermal performance. The heat transfer performance of PRHP was experimentally studied. Diamond and Al2O3 nanofluids with different mass concentrations and nanoparticle sizes were applied and compared with deionized water. The experiments were performed under the conditions of different heat inputs, rotational speeds, and different filling ratios. At the same filling ratio, there was a significant reduction in thermal resistance with nanofluids as compared with deionized water. Under the heat input of 140 W, the thermal resistance decreases by about 17.6

Advancing industrial waste heat recovery necessitates minimizing thermal energy loss through enhanced dropwise condensation heat transfer. This study investigates the synergistic interplay of surface architecture and wettability modulation, employing hydrophobic (HO), superhydrophilic (SHI), and hybrid biphilic (HS) designs to optimize dropwise condensation. Engineered copper surfaces, including flat surfaces (FS), gradient groove surfaces (GS), and their wettability patterned variants were fabricated and evaluated for condensation performance. Integrated visualization experiments demonstrate that intrinsically hydrophilic gradient groove surfaces (GS) achieve superior dropwise condensation via synergistic capillary action, dual Laplace pressure gradients, and gravitational effects. Conversely, hydrophobic patterning on flat surfaces (HO-FS) enhances condensation by promoting accelerated droplet nucleation and departure. Critically, optimal groove spacing was identified to balance rapid surface renewal with minimized thermal resistance, providing fundamental mechanistic insights for designing high-efficiency condensers in sustainable energy systems.

Radial rotating oscillating heat pipes (R-OHPs) have excellent thermal performance and great potential for application in the thermal management of rotatory machinery. However, the heat transport behavior and temperature characteristics of R-OHPs are complex, and their understanding is still limited, hence necessitating further research. In this study, thanks to an experimental investigation involving a copper R-OHP running with acetone and water, its thermal performance is evaluated, and then the temperature characteristics are analyzed by nonlinear dynamic analysis. The study reveals that the effective heat transfer coefficient of R-OHPs undergoes a notable increase with rising rotational speed, exhibiting a peak at a threshold speed value. Such a peak is present irrespectively of the working fluid, and, after exceeding the threshold, higher rotational speeds lead to a lower thermal performance. Based on nonlinear dynamic analysis, the power spectrum density of the evaporator temperature indicates a lack of dominant frequency in temperature signals, suggesting a complex behavior characterized by random oscillations of vapor slugs and liquid plugs. In order to better understand how strong the chaotic behavior is, an autocorrelation analysis was carried out, the OHP at static state has a stronger chaos than R-OHPs. The correlation dimension analysis of the evaporator temperature provides values ranging from 1.2 to 1.6, which together with the Lyapunov exponent calculations, further support an evident chaotic nature of R-OHPs.

Microwave modules, as the core elements of modern electronic systems, are evolving toward lead-free and highperformance designs. However, the employment of leaded solders, step soldering processes, and rework operations inevitably leads to hybrid solder joints of SnPbAg and SnAgCu (SAC), whose performance on Au/Ni/MoCu substrates remains underexplored. In this research, SnPbAg-xSAC (x = 25 wt %, 50 wt %, 75 wt %) hybrid solders were fabricated via a melting-casting method to assess the performance of hybrid solder joints comprehensively. Experimental results indicated that SnPbAg-xSAC hybrid solders significantly suppressed gold embrittlement compared to the SnPbAg solder. The shear strength and toughness of hybrid solder joints were improved via the grain refinement strengthening mechanism. Particularly, the SnPbAg-75 %SAC solder joints achieve the highest shear strength, reaching 43.4 +/- 1 MPa, under the synergistic effects of fine-grain strengthening and solid-solution strengthening. Furthermore, with the incorporation of 75 wt % SAC, the fracture mode of the solder joints transitioned from dominant intermetallic compound cleavage fracture to controlled ductile fracture. This research provides a theoretical basis for evaluating the performance of hybrid solder joints in microwave modules and puts forward new ideas for the development of solder materials in electronic packaging.

Objective CVD diamond is a hard and brittle material of wide applications,but the disordered arrangement of coarse grains in polycrystalline CVD diamond leads to uneven surface.The commonly used methods for CVD diamond processing are ultra-precision grinding and chemical-mechanical polishing,but generally of low efficiency and tool life.The efficiency of laser ablation depends on the optical and thermal properties of the laser,which provides a highly directional and localised energy source for diamond processing.Therefore,laser proessing is suitable for CVD diamonds with high hardness and wear resistance.It is necessary to study the influence of laser parameters on the surface morphology and surface damage to achieve the parameters optimization for nanosecond laser polishing of CVD diamond. Methods In this study,the surface generation process of laser ablated CVD diamond was firstly investigated by finite element simulation,and then the influence of laser processing parameter on the surface roughness and surface topographic characteristics of CVD diamond was investigated by single factor experiment.The surface roughness was measured using a 3D laser confocal microscope,and the surface topographic features of the workpieces were examined using a scanning electron microscope.The effects of laser incidence angle,laser power,laser scanning speed and scanning times on the surface roughness and surface topographic features of CVD diamond were achieved(Fig.6,Fig.11,Fig.14). Results and Discussions The results of finite element simulation(Fig.4)show that the incidence angles of the laser affect the polished surface,and the greater laser incidence angle,the smaller removal depth of the material.The laser polishing of CVD diamond were carried out with different laser incidence angles and powers,and the experimental results(Fig.6)were consistent with FEM.When the laser power is higher,the surface roughness of the material decreases with increasing incident angle,while the effect of the laser incident angle on the surface roughness drops significantly when the laser power is lower.The laser polishing of CVD diamond under different laser scanning speeds(Fig.11)shows that the surface roughness of the material decreases firstly and then increases with the growth of laser scanning speed.When the scanning speed was lower,the a great number of larger-size graphite grains and grooves formed(Fig.13),and when the scanning speed was higher,the surface turned to be relatively flat but with a lot of small cracks among the graphite grains.Finally,different laser scanning times of CVD diamond(Fig.14)show that the surface roughness of the material firstly decreases and then increases with the increase of the number of laser scanning times.A growing number of laser scanning times leads to a number of cracks on the diamond surface,which worsens the surface roughness(Fig.16). Conclusions In this study,the surface generation process of laser ablation of CVD diamond is investigated by finite element simulation and experiments,and the influence law of nanosecond laser processing parameters on the surface morphology and surface damage of CVD diamond is explored to achieve the optimization of nanosecond laser polishing parameters.The experimental results show that the increase of the laser incident angle can weaken the trapped light effect on the material surface,which can effectively improve the surface roughness of the material,and the greater laser incident inclination angle,the lower processing depth of the material surface.After nanosecond laser processing,a graphite layer is formed on the surface of CVD diamond,and surface grooves grooves and other damages appears when the laser power is higher,which can be suppressed by increasing the laser incident angle.The cracks on the surface of the material are attributed to the tensile stress in the graphite layer after cooling,and the size and number of cracks can be reduced by increasing laser incidence angle and decreasing laser power.Finally,the surface roughness(Sa)of CVD diamond dropped to be 1.3 μm by controlling the parameters,including laser incidence angle,laser power and laser scanning speed.

A significant amount of heat can be generated during the operation of rotary machinery, which degrades its working performance and lifetime. It has been proven that, under radial rotation conditions, pulsating heat pipes (PHPs) can operate with good thermal performance. PHPs have excellent potential for application in rotary machinery, owing to their enhanced heat transfer and material duration. Experimental studies on radially rotating PHPs remain scarce, and further in-depth physical understanding is required to achieve a better thermal design for practical configurations. In this study, the effects of centrifugal acceleration and heat flux on the heat transport in radially rotating PHPs were investigated in detail. The results demonstrate that centrifugal acceleration can promote the circular motion of chains of liquid plugs and vapor slugs with an improvement in thermal performance, particularly above a given heat flux threshold and a critical value of the rotation velocity. In addition, by considering the key influencing parameters, a semi-empirical correlation of dimensionless numbers was built to estimate the heat transport. Additionally, dimensionless numbers, i.e., Weber number, temperature number (ΔT/Tev), and a newly-defined number (Ψ1, represents the influence of heat flux, surface tension and centrifugal acceleration), significantly impact the thermal performance.

Monitoring tool condition and remaining useful life (RUL) are vital in preventing the occurrence of excessive tool wear. This paper develops a novel dynamic data-driven degradation method for monitoring the RUL of cutting tools. In sensor-data collection, vibration, sound, and power external sensors and built-in data are gathered from the machine tool. In multi-feature selection and dynamic model updating, a decision-level fusion method of spanning multi-domain features is designed to dynamically utilize a global prediction error for selecting and fusion degradation features, which are associated with the cutting tool life in the degradation model. A rolling HI-RUL mapping is established in RUL prediction by employing a historical health indicator curve, which estimates the RUL of cutting tool with a given threshold. The effectiveness of proposed method was assessed through two run-to-failure experiments of cutting tools, showing that an average global prediction error is reduced to 4.07%.

A large amount of grinding heat is generated during the high-efficiency grinding process, which causes workpiece burnout. Although the utilization of a significant quantity of coolant can lower grinding temperature, it inevitably leads to environmental pollution and damages the health of operators. To reduce coolant usage, it is worth considering reducing the grinding temperature by enhancing the thermal performance of grinding wheels. In this study, a new type of phase change heat storage grinding wheel (PCHS grinding wheel) with a high heat transfer coefficient and large heat capacity is developed utilizing the boiling heat transfer principle and heat storage technology, whose structure and working principle are explained. In addition, a visual device was made to simulate the internal heat transfer and heat storage process of PCHS grinding wheels, and the effects of heat flux, injection amount of working fluid, heat dissipation conditions, and heat capacity on the boiling heat transfer coefficient, start-up time of working fluid entering the boiling heat transfer state, and grinding temperature control are analyzed. Eventually, a comparative experiment of dry grinding 45 steel was carried out. Results show that the boiling heat transfer coefficient of PCHS grinding wheels is in the range of 1000–7000 W/m2·°C, the start-up time is 5–8 s, and increasing the heat capacity of grinding wheels can effectively slow down the heating rate. Besides, the grinding temperature is reduced by 22