Advances in Manufacturing

Nanobiolubricant grinding: a comprehensive review

Yu-Xiang Song, Chang-He Li, Zong-Ming Zhou, Bo Liu, Shubham Sharma, Yusuf Suleiman Dambatta, Yan-Bin Zhang, Min Yang, Teng Gao, Ming-Zheng Liu, Xin Cui, Xiao-Ming Wang, Wen-Hao Xu, Run-Ze Li, Da-Zhong Wang

2025, 13(1): 1-42. doi:10.1007/s40436-023-00477-7

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Minimum quantity lubrication (MQL), which considers the cost, sustainability, flexibility, and quality, has been actively explored by scholars. Nanoadditive phases have been widely investigated as atomizing media for MQL, aimed at enhancing the heat transfer and friction reduction performance of vegetable-oil-based biolubricants. However, the industrial application of nano-enhanced biolubricants (NEBL) in grinding wheels and workpiece interfaces as a cooling and lubricating medium still faces serious challenges, which are attributed to the knowledge gap in the current mapping between the properties and grindability of NEBL. This paper presents a comprehensive literature review of research developments in NEBL grinding, highlighting the key challenges, and clarifies the application of blind spots. Firstly, the physicochemical properties of the NEBL are elaborated from the perspective of the base fluid and nanoadditive phase. Secondly, the excellent grinding performance of the NEBL is clarified by its distinctive film formation, heat transfer, and multiple-field mobilization capacity. Nanoparticles with high thermal conductivity and excellent extreme-pressure film-forming properties significantly improved the high-temperature and extreme-friction conditions in the grinding zone. Furthermore, the sustainability of applying small amounts of NEBL to grinding is systematically evaluated, providing valuable insights for the industry. Finally, perspectives are proposed to address the engineering and scientific bottlenecks of NEBL. This review aims to contribute to the understanding of the effective mechanisms of NEBL and the development of green grinding technologies.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-023-00477-7

Grinding of particle-reinforced metal matrix composite materials: current status and prospects

Xiao-Fei Lei, Wen-Feng Ding, Biao Zhao, Chuan Qian, Zi-Ang Liu, Qi Liu, Dong-Dong Xu, Yan-Jun Zhao, Jian-Hui Zhu

2025, 13(1): 43-68. doi:10.1007/s40436-024-00518-9

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Particle-reinforced metal matrix composites (PMMCs) exhibit exceptional mechanical properties, rendering them highly promising for extensive applications in aerospace, military, automotive, and other critical sectors. The distinct physical properties of the matrix and reinforcement result in a poor machining performance, particularly owing to the continuous increase in the particle content of the reinforcement phase. This has become a major obstacle in achieving the efficient and precise machining of PMMCs. The grinding process, which is a highly precise machining method, has been extensively employed to achieve precision machining of metal matrix composites. Firstly, the classification of PMMCs is presented, and the grinding removal mechanism of this material is elaborated. Recent studies have examined the impact of various factors on the grinding performance, including the grinding force, grinding temperature, grinding force ratio, specific grinding energy, surface integrity, and wheel wear. The application status of various grinding methods for PMMCs is also summarized. Finally, the difficulties and challenges in achieving high-efficiency precision grinding technology for PMMCs are summarized and discussed.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00518-9

Surface quality evaluation of cold plasma and NMQL multi-field coupling eco-friendly micro-milling 7075-T6 aluminum alloy

Zhen-Jing Duan, Shuai-Shuai Wang, Shu-Yan Shi, Ji-Yu Liu, Yu-Heng Li, Zi-Heng Wang, Chang-He Li, Yu-Yang Zhou, Jin-Long Song, Xin Liu

2025, 13(1): 69-87. doi:10.1007/s40436-024-00530-z

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Micromilling has been extensively employed in different fields such as aerospace, energy, automobiles, and healthcare because of its efficiency, flexibility, and versatility in materials and structures. Recently, nanofluid minimum quantity lubrication (NMQL) has been proposed as a green and economical cooling and lubrication method to assist the micromilling process; however, its effect is limited because high-speed rotating tools disturb the surrounding air and impede the entrance of the nanofluid. Cold plasma can effectively enhance the wettability of lubricating droplets on the workpiece surface and promote the plastic fracture of materials. Therefore, the multifield coupling of cold plasma and NMQL may provide new insights to overcome this bottleneck. In this study, experiments on cold plasma + NMQL multifield coupling-assisted micromilling of a 7075-T6 aluminum alloy were conducted to analyze the three-dimensional (3D) surface roughness (S_a), surface micromorphology, burrs of the workpiece, and milling force at different micromilling depths. The results indicated that, under cold plasma + NMQL, the workpiece surface micromorphology was smooth with fewer burrs. In comparison with dry, N₂, cold plasma, and NMQL, the S_a values at different cutting depths (5, 10, 15, 20 and 30 μm) were relatively smaller under cold plasma + NMQL with 0.035, 0.036, 0.041, 0.043 and 0.046 μm, which were respectively reduced by 38.9%, 45.7%, 45.9%, 47% and 48.9% when compared to the dry. The effect of cold plasma + NMQL multifield coupling-assisted micromilling on enhancing the workpiece surface quality was analyzed using mechanical analysis of tensile experiments, surface wettability, and X-ray photoelectron spectroscopy (XPS).

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00530-z

Surface roughness model of ultrasonic vibration-assisted grinding GCr15SiMn bearing steel and surface topography evaluation

Xiao-Fei Lei, Wen-Feng Ding, Biao Zhao, Dao-Hui Xiang, Zi-Ang Liu, Chuan Qian, Qi Liu, Dong-Dong Xu, Yan-Jun Zhao, Jian-Hui Zhu

2025, 13(1): 88-104. doi:10.1007/s40436-024-00522-z

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It is necessary to improve the surface performance of bearing rings and extend the service life of bearings. In this study, ultrasonic vibration-assisted grinding (UVAG) was applied to process GCr15SiMn bearing steel, considering the effects of grinding-wheel wear, overlap of abrasive motion tracks under ultrasonic conditions, elastic yield of abrasives, and elastic recovery of the workpiece on the machined surface. In addition, a novel mathematical model was established to predict surface roughness (R_a). The proposed model was validated experimentally, and the predicted and experimental results showed similar trends under various processing parameters, with both within an error range of 12%-20%. The relationships between the machining parameters and R_a for the two grinding methods were further investigated. The results showed that increases in the grinding speed and ultrasonic amplitude resulted in a decrease in R_a, whereas increases in the grinding depth and workpiece speed resulted in an increase in R_a. Furthermore, the R_a values obtained using the UVAG method were lower than those of conventional grinding (CG). Finally, the influence of ultrasonic vibration on the surface topography was investigated. Severe tearing occurred on the CG surface, whereas no evident defects were observed on the ultrasonically machined surface. The surface quality was improved by increasing the ultrasonic amplitude such that it did not exceed 4 μm, and a further increase in ultrasonic amplitude deteriorated the surface topography. Nevertheless, this improvement was superior to that of the CG surface and was consistent with the variation in R_a.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00522-z

High-speed grinding: from mechanism to machine tool

Yu-Long Wang, Yan-Bin Zhang, Xin Cui, Xiao-Liang Liang, Run-Ze Li, Ruo-Xin Wang, Shubham Sharma, Ming-Zheng Liu, Teng Gao, Zong-Ming Zhou, Xiao-Ming Wang, Yusuf Suleiman Dambatta, Chang-He Li

2025, 13(1): 105-154. doi:10.1007/s40436-024-00508-x

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High-speed grinding (HSG) is an advanced technology for precision machining of difficult-to-cut materials in aerospace and other fields, which could solve surface burns, defects and improve surface integrity by increasing the linear speed of the grinding wheel. The advantages of HSG have been preliminarily confirmed and the equipment has been built for experimental research, which can achieve a high grinding speed of more than 300 m/s. However, it is not yet widely used in manufacturing due to the insufficient understanding on material removal mechanism and characteristics of HSG machine tool. To fill this gap, this paper provides a comprehensive overview of HSG technologies. A new direction for adding auxiliary process in HSG is proposed. Firstly, the combined influence law of strain hardening, strain rate intensification, and thermal softening effects on material removal mechanism was revealed, and models of material removal strain rate, grinding force and grinding temperature were summarized. Secondly, the constitutive models under high strain rate boundaries were summarized by considering various properties of material and grinding parameters. Thirdly, the change law of material removal mechanism of HSG was revealed when the thermodynamic boundary conditions changed, by introducing lubrication conditions such as minimum quantity lubrication (MQL), nano-lubricant minimum quantity lubrication (NMQL) and cryogenic air (CA). Finally, the mechanical and dynamic characteristics of the key components of HSG machine tool were summarized, including main body, grinding wheel, spindle and dynamic balance system. Based on the content summarized in this paper, the prospect of HSG is put forward. This study establishes a solid foundation for future developments in the field and points to promising directions for further exploration.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00508-x

Effects of tool coating and tool wear on the surface and chip morphology in side milling of Ti₂AlNb intermetallic alloys

Xin Wang, Qing-Liao He, Biao Zhao, Wen-Feng Ding, Qi Liu, Dong-Dong Xu

2025, 13(1): 155-166. doi:10.1007/s40436-024-00527-8

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Ti₂AlNb intermetallic alloys, which belong to the titanium aluminum (TiAl) family, are currently being extensively researched and promoted in the aerospace industry because of their exceptional properties, including low density, high-temperature strength, and excellent oxidation resistance. However, the excellent fracture toughness of the material leads to the formation of surface defects during machining, thereby affecting the quality of the machined surface. In this study, Ti₂AlNb intermetallic alloys were subjected to side-milling trials to investigate the influence of tool coating and tool wear on both the machined surface quality and chip morphology. Specifically, the tool life, machined surface roughness, surface morphology, surface defects, and chip morphology were investigated in detail. The results indicated that the tool coating provided a protective effect, resulting in a threefold increase in the service life of the coated end mill compared to that of the uncoated one. A coated end mill yields a superior machined surface topography, as evidenced by reduced roughness and a more consistent morphology. Tool wear has a significant effect on the morphology of machined surfaces. The occurrence of material debris and feed marks became increasingly severe as the tool wore off. The chip morphology was not significantly affected by the tool coating. However, tool wear results in severe tearing along the chip edge, obvious plastic flow on the non-free surface, and a distinct lamellar structure on the free surface.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00527-8

A mechanism-data hybrid-driven modeling method for predicting machine tool-cutting energy consumption

Yue Meng, Sheng-Ming Dong, Xin-Sheng Sun, Shi-Liang Wei, Xian-Li Liu

2025, 13(1): 167-195. doi:10.1007/s40436-024-00526-9

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High-quality development in the manufacturing industry is often accompanied by high energy consumption. The accurate prediction of the energy consumption of computer numerical control (CNC) machine tools, which plays a vital role in manufacturing, is of great importance in energy conservation. However, the existing research ignores the impact of multi-factor energy losses on the performance of machine tool energy consumption prediction models. The existing models must be selected and verified several times to determine the appropriate hyperparameters. Therefore, in this study, a machine tool energy consumption prediction method based on a mechanism and data-driven model that considers multi-factor energy losses and hyperparameter dynamic self-optimization is proposed to improve the accuracy and reduce the difficulty of hyperparameter tuning. The proposed multi-factor energy-loss prediction model is based on the theoretical prediction model of machine-tool cutting energy consumption. After creating the model, a hyperparameter search space embedding a tree-structured Parzen estimator (TPE) was designed based on Hyperopt to dynamically self-optimize the hyperparameters in the deep neural network (DNN) model. Finally, two sets of experiments were designed for verification and comparison with the theoretical and data models. The results showed that the energy consumption prediction performances of the proposed hybrid model in the two sets of experiments were 99% and 97%.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00526-9

Heterogeneous ablation behavior of SiC_f/SiC composite by nanosecond pulse laser

Jia-Heng Zeng, Quan-Li Zhang, Yu-Can Fu, Jiu-Hua Xu

2025, 13(1): 196-210. doi:10.1007/s40436-024-00532-x

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Silicon carbide fiber-reinforced silicon carbide composites are preferred materials for hot-end structural parts of aero-engines. However, their anisotropy, heterogeneity, and ultra-high hardness make them difficult to machine. In this paper, 2.5-dimensional braided SiC_f/SiC composites were processed using a nanosecond pulsed laser. The temperature field distribution at the laser ablated spot is analyzed through finite element modeling (FEM), and the ablation behavior of the two main components, SiC fiber and SiC matrix, is explored. A plasma plume forms when the pulse energy is sufficiently high, which increases with growing energy. The varied ablation behavior of the components is investigated, including the removal rate, ablative morphology, and phase transition. The ablation thresholds of SiC matrix and SiC fiber are found to be 2.538 J/cm² and 3.262 J/cm², respectively.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00532-x

Grinding defect characteristics and removal mechanism of unidirectional C_f/SiC composites

Chong-Jun Wu, Fei Liu, Jia-Zhou Wen, Pei-Yun Xia, Steven Y. Liang

2025, 13(1): 211-228. doi:10.1007/s40436-024-00521-0

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Owing to their brittleness and heterogeneity, achieving carbon fiber-reinforced silicon carbide ceramic (C_f/SiC) composites with ideal dimensional and shape accuracy is difficult. In this study, unidirectional C_f materials were subjected to orthogonal grinding experiments using different fiber orientations. Through a combined analysis of the surface morphology and grinding force after processing, the mechanism underlying the effect of the fiber orientation on the surface morphology of the material was explained. The surface roughness of the material was less affected by the process parameters and fluctuated around the fiber radius scale; the average surface roughness (R_a) in the direction of scratching parallel (SA) and perpendicular (SB) to the fiber direction was 4.21-5.00 μm and 4.42-5.26 μm, respectively; the material was mainly removed via the brittle removal mechanism; and the main defects of the fiber in the SA direction were tensile fracture and extrusion fracture; the main defects of the fiber in the SB direction were bending fracture, shear fracture, and fiber debonding. The grinding parameters influenced the grinding force in the order: depth of cut > feed rate > wheel speed. The grinding force increased with an increase in the feed rate or depth of cut and decreased with an increase in the wheel speed. Moreover, increasing the depth of cut was more effective in decreasing the grinding force and improving the material removal efficiency than adjusting the rotational speed of the workpiece and the rotational speed of the grinding wheel. The specific grinding energy decreased with an increase in the feed rate or depth of cut, and increased with an increase in the grinding wheel speed.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00521-0

Electrochemical grinding of honeycomb seals using sodium dodecylbenzene sulfonate as an eco-friendly inhibitor: machining principle and performance evaluation

Jin-Hao Wang, Lu Wang, Han-Song Li, Ning-Song Qu

2025, 13(1): 229-244. doi:10.1007/s40436-024-00531-y

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To enhance the performance of aero-engines, honeycomb seals are commonly used between the stator and rotor to reduce leakage and improve mechanical efficiency. Because of the thin-walled and densely distributed honeycomb holes, machining defects are prone to occur during manufacturing. Electrochemical grinding (ECG) can minimize machining deformation because it is a hybrid process involving electrochemical dissolution and mechanical grinding. However, electrolysis will generate excessive corrosion on the honeycomb surface, which affects the sealing capability and operational performance. In this study, an ECG method using an electrolyte of 10% (mass fraction) NaCl is proposed to machine the inner cylindrical surface of the honeycomb seal, and an eco-friendly inhibitor, sodium dodecylbenzene sulfonate (SDBS), is introduced to the electrolyte to inhibit corrosion of the honeycomb structure. A theoretical relationship between the voltage and feed rate during ECG is proposed, and the excessive corrosion of the honeycomb single-foiled segment is used as a measurement of the impact of electrolysis. The corrosion inhibition efficiency of SDBS on the honeycomb material in 10% (mass fraction) NaCl solution is evaluated through electrochemical tests, and the suitable feed rate and optimal concentration of SDBS are determined through ECG experiments. Additionally, the corrosion inhibition effect of SDBS is validated through four groups of comparative experiments. The results indicate that the inhibition efficiency of SDBS increases with increasing concentration, reaching the maximum of 73.44%. The optimal SDBS mass fraction is determined to be 0.06%. The comparative experiments show that excessive corrosion is reduced by more than 40%. This establishes ECG as an effective and environmentally friendly processing method for honeycomb seals by incorporating SDBS into a 10% (mass fraction) NaCl solution.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00531-y

Mechanism and machinability in novel electroplastic-assisted grinding ductile iron

Jia-Hao Liu, Dong-Zhou Jia, Chang-He Li, Yan-Bin Zhang, Ying Fu, Zhen-Lin Lv, Shuo Feng

2025, 13(1): 245-263. doi:10.1007/s40436-024-00533-w

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Owing to the hard brittle phase organization in their matrixes, brittle materials are prone to the formation of pits and cracks on machined surfaces under extreme grinding conditions, which severely affect the overall performance and service behavior of machined parts. Based on the electroplastic effect of pulsed currents during material deformation, this study investigates electroplastic-assisted grinding with different electrical parameters (current, frequency, and duty cycle). The results demonstrate that compared to conventional grinding, the pulsed current can significantly decrease the surface roughness (S_a) of the workpiece and reduce surface pits and crack defects. The higher the pulsed current, the more pronounced the improvement in the surface quality of the workpiece. Compared to traditional grinding, when the pulsed current is 1 000 A, S_a decreases by 46.4%, and surface pit and crack defects are eliminated. Under the same pulse-current amplitude and frequency conditions, the surface quality continues to improve as the duty cycle increases. When the duty cycle is 75%, S_a reaches a minimum of 0.749 μm. However, the surface quality is insensitive to the pulsed-current frequency. By investigating the influence of pulsed electrical parameters on the surface quality of brittle material under grinding conditions, this study provides a theoretical basis and technical support for improving the machining quality of hard, brittle materials.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00533-w

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