High Precision Abrasive Machining: Machines, Processes and Systems

A special issue of Machines (ISSN 2075-1702). This special issue belongs to the section "Advanced Manufacturing".

Deadline for manuscript submissions: closed (31 January 2023) | Viewed by 21984

Special Issue Editors

School of Mechanical Engineering, Shenyang University of Technology, Shenyang 110870, China
Interests: abrasive machining processes; grinding wheels; abrasive blades; polishing
College of Engineering, Design and Physical Sciences, Brunel University London, Uxbridge, London UB8 3PH, UK
Interests: design of high precision machines; air-bearings design; micro cutting; ultraprecision machining; smart tooling
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Special Issue Information

Dear Colleagues,

High-precision abrasive machining is an essential process for high-value manufacturing. It involves machines, processes and systems often reflected in high-performance grinding and/or abrasive machines, a complex abrasive cutting process, super-hard grinding wheels or ultra-thin abrasive blades, automated high-precision machining systems which are integrated with fluid film bearing spindles and slideways. Their typical manufacturing applications range from machining automotive engine components and aerofoil structures to semiconductor wafers dicing. Abrasive machining and/or grinding is an interesting finishing process for high-precision manufacturing, and is embraced by manufacturers and professionals worldwide in precision engineering practices, research and development.

The aim of this Special Issue is to provide a forum for researchers and practitioners to review the state of the art in high-precision abrasive machining, particularly the machines, processes, systems and the underlying science and fundamentals, and to identify possible directions for future R&D and applications. Original contributions should discuss the innovative design, development and application of these systems, with particular emphasis on the knowledge, innovation and insights accumulated over the past two decades, and also on opportunities and implications for the future of the 21st century. Possible topics include, but are not limited to,

  • High-precision machines;
  • Abrasive machining;
  • Design and development of high-precision grinding machines;
  • Grinding processes;
  • Design of grinding wheels and abrasive blades;
  • Abrasive machining systems;
  • Semiconductor wafer dicing;
  • 3D printing and additive manufacturing of grinding wheels and tools;
  • Spindles and slideways for grinding machines;
  • Abrasive flow machining (AFM);
  • Abrasive/water jet machining;
  • Multiscale multiphysics modelling, analysis and simulations.

Prof. Dr. Mark J. Jackson
Prof. Dr. Zewei Yuan
Prof. Dr. Kai Cheng
Guest Editors

Manuscript Submission Information

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

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • high-precision machines
  • abrasive machining
  • grinding machines
  • grinding processes
  • grinding wheels
  • abrasive blades
  • abrasive machining systems
  • semiconductor wafer dicing

Published Papers (11 papers)

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Research

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15 pages, 5045 KiB  
Article
Study of Diamond Wheel Wear Based on the Principle of Frictional Energy Distribution in Ultrasonic-Assisted Grinding Trajectories
by Longfei Zhao, Sisi Li, Xianglei Zhang, Hongming Zhou and Qiang Wang
Machines 2022, 10(12), 1191; https://doi.org/10.3390/machines10121191 - 08 Dec 2022
Viewed by 931
Abstract
In the grinding process, the friction energy generated by grains and the workpiece in the grinding zone will affect the service life of the grinding wheel. Ultrasonic-vibration-assisted grinding (UVAG) can reduce the friction force and reduce the generation of friction energy during grinding. [...] Read more.
In the grinding process, the friction energy generated by grains and the workpiece in the grinding zone will affect the service life of the grinding wheel. Ultrasonic-vibration-assisted grinding (UVAG) can reduce the friction force and reduce the generation of friction energy during grinding. In this work, the wear mechanism of grinding wheels in UVAG is discussed in detail from the perspective of the grain grinding trajectory and tribology. The results show that UVAG has a smaller friction force than conventional grinding (CG). Furthermore, when the initial included angles of grains are 90° and 150°, the friction energy of a single grinding surface in UVAG is reduced by 24% and 37% compared with that of CG, respectively. In UVAG, the grains are prone to microfractures, and the self-sharpening ability of the grinding wheel is enhanced, which can obtain a lower grinding force and better grinding surface quality. Full article
(This article belongs to the Special Issue High Precision Abrasive Machining: Machines, Processes and Systems)
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21 pages, 10163 KiB  
Article
Developing and Testing the Proto Type Structure for Micro Tool Fabrication
by Hang Xiao, Xiaolong Hu, Shaoqing Luo and Wei Li
Machines 2022, 10(10), 938; https://doi.org/10.3390/machines10100938 - 16 Oct 2022
Cited by 1 | Viewed by 1205
Abstract
Compared with traditional machine tools, the micro machine tools have advantages of small volume, low cost, less energy consumption, high efficiency and high flexibility. Therefore, it is regarded as an important equipment for micro-cutting machining which has been used widely all over the [...] Read more.
Compared with traditional machine tools, the micro machine tools have advantages of small volume, low cost, less energy consumption, high efficiency and high flexibility. Therefore, it is regarded as an important equipment for micro-cutting machining which has been used widely all over the world and. As a key component of the micro-cutting machine tools, the body structure directly influences the machining performance. Thus, an integral column and base structure for micro machining tools was proposed in this work, and the detailed structural parameters were designed based on parameter analysis. Besides, the static and dynamic performance of the proposed machine were analyzed and compared between the integral structure and the separated one. The deformation and stress of the proposed structures under typical working conditions were studied by numerical simulation, along with the natural frequencies, vibration modes and frequency response peaks. Further, optimization was performed on the integral body structure, the prototype of the micro-machine tool was trial-produced, and the positioning accuracy of each coordinate axis was qualitatively analyzed. In addition, the micro-milling test was carried out with 6061 aluminum alloy to show the performance of the novel cutting machine. The results revealed that the proposed integrated micro-machine bed structure is superior to the separated structure in terms of static deformation and harmonic response characteristics, with good comprehensive mechanical properties, greatly improved static and dynamic performance of the machine tool, significantly improved structural accuracy, improved processing quality of the specimen and good application value. Full article
(This article belongs to the Special Issue High Precision Abrasive Machining: Machines, Processes and Systems)
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13 pages, 4639 KiB  
Article
Grinding Performance of Laser Cladding WC/Fe Coatings by Different Adding Methods of WC Particles
by Qiulian Dai, Lianhong Liu, Fangyi You and Canbin Luo
Machines 2022, 10(10), 910; https://doi.org/10.3390/machines10100910 - 08 Oct 2022
Cited by 1 | Viewed by 1288
Abstract
Laser cladding coatings generally need a follow-up grinding process to acquire the desired dimensional accuracy and surface roughness. In this paper, grinding experimental studies were set up to investigate the grinding performance of iron-based matrix composite coatings (WC/Fe with in situ and ex [...] Read more.
Laser cladding coatings generally need a follow-up grinding process to acquire the desired dimensional accuracy and surface roughness. In this paper, grinding experimental studies were set up to investigate the grinding performance of iron-based matrix composite coatings (WC/Fe with in situ and ex situ WC particles), using two types of grinding wheels. The influence of grinding parameters such as the cut depth, wheel speed and type of grinding wheel on grinding forces, force ratio, specific energy, surface roughness and the surface appearance of the two coatings was studied. The forming mechanism of the subsurface damages on the two ground coatings was discussed. Experimental results revealed that there were obvious differences between the two coatings in grinding forces, surface roughness and morphology, especially in the subsurface damages. These were attributed to their difference in size and the distribution of the WC particles, as well as their different mechanical properties. Full article
(This article belongs to the Special Issue High Precision Abrasive Machining: Machines, Processes and Systems)
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15 pages, 5561 KiB  
Article
Machining Performance for Ultrasonic-Assisted Magnetic Abrasive Finishing of a Titanium Alloy: A Comparison with Magnetic Abrasive Finishing
by Fujian Ma, Ziguang Wang, Yu Liu, Zhihua Sha and Shengfang Zhang
Machines 2022, 10(10), 902; https://doi.org/10.3390/machines10100902 - 06 Oct 2022
Cited by 4 | Viewed by 1426
Abstract
Titanium alloys are widely used in aerospace, the military industry, electronics, automotive fields, etc., due to their excellent properties such as low density, high strength, high-temperature resistance, and corrosion resistance. Many components need to be finished precisely after being cut in these applications. [...] Read more.
Titanium alloys are widely used in aerospace, the military industry, electronics, automotive fields, etc., due to their excellent properties such as low density, high strength, high-temperature resistance, and corrosion resistance. Many components need to be finished precisely after being cut in these applications. In order to achieve high-quality and high-efficiency finishing of titanium alloys, ultrasonic-assisted magnetic abrasive finishing (UAMAF) was introduced in this research. The machining performance for UAMAF of a titanium alloy was studied by experimentally comparing UAMAF and magnetic abrasive finishing (MAF). The results show that the cutting force of UAMAF can reach 2 to 4 times that of MAF, and it decreases rapidly with the increase in the machining gap due to the energy loss of ultrasonic impact in the transmission between magnetic abrasives. The surface roughness of UAMAF can reach about Ra 0.075 μm, which is reduced by about 59% compared with MAF. The main wear type of the magnetic abrasive is that the diamond grits fell off the magnetic abrasive in both UAMAF and MAF. The uniform wear of the magnetic abrasive is realized, and the utilization ratio of the magnetic abrasive is obviously improved in UAMAF. Full article
(This article belongs to the Special Issue High Precision Abrasive Machining: Machines, Processes and Systems)
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23 pages, 14473 KiB  
Article
Simulation of Magnetorheological Plane Polishing Scratch Creation Process and Suppression Method
by Meixuan Wang, Meng Nie, Yueming Liu and Haodong Guo
Machines 2022, 10(9), 812; https://doi.org/10.3390/machines10090812 - 15 Sep 2022
Viewed by 1200
Abstract
This study was conducted to simulate the causes of, and suppress, the scratch damage on the workpiece surface during magnetorheological surface polishing. The molecular dynamics method combined with polishing contact trajectory modeling was used to simulate the scratch damage formation process, and the [...] Read more.
This study was conducted to simulate the causes of, and suppress, the scratch damage on the workpiece surface during magnetorheological surface polishing. The molecular dynamics method combined with polishing contact trajectory modeling was used to simulate the scratch damage formation process, and the scratch damage morphology model was established by analyzing the scratch damage distribution characteristics in the magnetorheological plane polishing process. The effect of different process parameters on the scratch damage characteristics was predicted by simulation, and orthogonal experiments were designed to explore the preferred polishing process parameters that could suppress the scratch damage formation. Finally, it was further verified that the formation of scratch damage can be effectively suppressed by controlling the workpiece speed, polishing disc speed, and magnetic field generator speed, and adjusting the magnetic field eccentricity distance under the premise of ensuring the surface roughness and flatness of the workpiece. Full article
(This article belongs to the Special Issue High Precision Abrasive Machining: Machines, Processes and Systems)
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18 pages, 16665 KiB  
Article
Design and Optimization of the Surface Texture at the Hydrostatic Bearing and the Spindle for High Precision Machining
by Youyun Shang, Kai Cheng, Hui Ding and Shijin Chen
Machines 2022, 10(9), 806; https://doi.org/10.3390/machines10090806 - 13 Sep 2022
Cited by 5 | Viewed by 1657
Abstract
Hydrostatic bearing spindles are widely applied in high precision grinding and turning machines due to their good dynamic stability and rotational accuracy. However, under the condition of high-speed rotations, the heat generated by the friction of the oil film will cause the shear [...] Read more.
Hydrostatic bearing spindles are widely applied in high precision grinding and turning machines due to their good dynamic stability and rotational accuracy. However, under the condition of high-speed rotations, the heat generated by the friction of the oil film will cause the shear thinning effect. It not only reduces the rotation accuracy of the spindle but also reduces the service life of the spindle. The surface texture structure and configuration between the planes play the role of homogenizing oil film temperature and preventing the bearing surface wear caused by excessive concentration of temperature, which can change the relative motion from the inside of the oil film and thus improve the performance of the hydrostatic spindle more effectively. In this paper, the influence of the surface texture shape and height on the thrust bearing performance of the hydrostatic spindle is systematically investigated by comparative analysis. The CFD simulations are developed to analyze the computational results based on the theory of viscosity-temperature characteristics. The results show that when the height of the surface structure is 1 ~ 2 times the oil film thickness, the spindle bearing performance is the best. The average temperature in the bearing region is the lowest and the accuracy of the simulations was verified by experimental results. Full article
(This article belongs to the Special Issue High Precision Abrasive Machining: Machines, Processes and Systems)
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14 pages, 3508 KiB  
Article
Research on Adaptive Control of Grinding Force for Carbide Indexable Inserts Grinding Process Based on Spindle Motor Power
by Peng Chen, Xianglei Zhang, Ming Feng, Sisi Li, Xiaoming Pan and Wei Feng
Machines 2022, 10(9), 802; https://doi.org/10.3390/machines10090802 - 11 Sep 2022
Cited by 2 | Viewed by 1733
Abstract
The grinding force is the most sensitive physical measure of reaction loads in the grinding process. To enhance surface quality and assure high efficiency and stability of the grinding process, it is essential to accomplish adaptive control of the grinding force. This paper [...] Read more.
The grinding force is the most sensitive physical measure of reaction loads in the grinding process. To enhance surface quality and assure high efficiency and stability of the grinding process, it is essential to accomplish adaptive control of the grinding force. This paper suggests a grinding force adaptive control system based on spindle motor power feedback, considering the process–machine interaction. The spindle motor power is utilized as a proxy for the grinding force because of the mapping relationship between the two variables. The machine tool’s feed rate is automatically modified to achieve adaptive control of the grinding force, after assessing the discrepancy between the collected spindle motor power and the preset power. Finally, a cemented carbide tool grinding experiment was performed on a 2MZK7150 CNC tool grinder. During the experiment, the grinding force was precisely controlled between 80 and 100 N, ensuring machining quality and increasing machining efficiency. The experimental results show that the adaptive control system can meet the high-efficiency and high-quality machining requirements of cemented carbide rotary blades. Full article
(This article belongs to the Special Issue High Precision Abrasive Machining: Machines, Processes and Systems)
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17 pages, 5434 KiB  
Article
Sub-Fiber Scale Precision Dicing of Aramid Fiber-Reinforced Plastic Composites
by Quan Wen, Jintao Hu and Zewei Yuan
Machines 2022, 10(5), 334; https://doi.org/10.3390/machines10050334 - 03 May 2022
Cited by 5 | Viewed by 1778
Abstract
Aramid fiber-reinforced plastic (AFRP) composites are widely used in aerospace, rail transit, marine and military industries, due to their high specific strength, high impact resistance, fatigue resistance and excellent designable properties. In order to meet different application requirements, cutting processes need to be [...] Read more.
Aramid fiber-reinforced plastic (AFRP) composites are widely used in aerospace, rail transit, marine and military industries, due to their high specific strength, high impact resistance, fatigue resistance and excellent designable properties. In order to meet different application requirements, cutting processes need to be carried out, such as window opening, edge cutting and slit cutting. However, the characteristics of high tensile strength and toughness, low interlaminar strength, non-uniformity and anisotropy make AFRP composites a difficult-to-machine material. They are prone to produce rough cutting surfaces and cutting damages including burr, wire drawing, delamination, resin burn, material flanging, etc. To solve this problem, the ultra-thin diamond dicing blade was used for high-speed cutting of AFRP composites in sub-fiber scale in this research. The influence of process parameters on cutting force, cutting temperature, maximum spindle current, tool wear and cutting surface quality were investigated by establishing the cutting force model, L16(45) orthogonal experiment, single factor experiment, range analysis and variance analysis. The theoretical and experimental results show that cutting AFRP composites with ultra-thin diamond dicing blade can obtain smooth surfaces without common cutting damages. When the cutting speed is 91.11 m/s (spindle speed n = 30,000 r/min), the cutting depth is 0.2 mm and the feed speed is 5 mm/s, the surface roughness Ra can be as low as 32 nm, which realize the precision cutting of AFRP composites. Full article
(This article belongs to the Special Issue High Precision Abrasive Machining: Machines, Processes and Systems)
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15 pages, 3926 KiB  
Article
Study on Mechanism of Roundness Improvement by the Internal Magnetic Abrasive Finishing Process Using Magnetic Machining Tool
by Jiangnan Liu and Yanhua Zou
Machines 2022, 10(2), 112; https://doi.org/10.3390/machines10020112 - 02 Feb 2022
Cited by 6 | Viewed by 1557
Abstract
An internal magnetic abrasive finishing process using a magnetic machining tool was proposed for finishing the internal surface of the thick tubes. It has been proved that this process is effective for finishing thick tubes, and it can improve the roundness while improving [...] Read more.
An internal magnetic abrasive finishing process using a magnetic machining tool was proposed for finishing the internal surface of the thick tubes. It has been proved that this process is effective for finishing thick tubes, and it can improve the roundness while improving the roughness. However, the mechanism of improving the roundness is not clear, so it is necessary to study it theoretically. In this research, firstly, the roundness curve expression was derived using the principle of roundness measurement by the assumed center method, and the expression of roundness curve expanded by Fourier series was obtained. The influencing factors of roundness improvement were then analyzed. Secondly, the experiments were carried out on SUS304 stainless steel tubes. By confirming the mechanism analysis results and the experimental results, it was concluded that the internal magnetic abrasive finishing process using the magnetic machining tool was effective for improving the roundness of the thick tubes whose thickness is from 10 mm to 30 mm. As the thickness of the tube increased, the improvement in roundness decreased. Full article
(This article belongs to the Special Issue High Precision Abrasive Machining: Machines, Processes and Systems)
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17 pages, 4818 KiB  
Article
Study on Corrective Abrasive Finishing for Workpiece Surface by Using Magnetic Abrasive Finishing Processes
by Yulong Zhang and Yanhua Zou
Machines 2022, 10(2), 98; https://doi.org/10.3390/machines10020098 - 27 Jan 2022
Cited by 3 | Viewed by 2428
Abstract
In order to improve the plane quality of the workpiece shape accuracy, a correction abrasive finishing method is proposed. This method is used to achieve the effect of correcting the workpiece surface by changing the finishing conditions of different areas according to the [...] Read more.
In order to improve the plane quality of the workpiece shape accuracy, a correction abrasive finishing method is proposed. This method is used to achieve the effect of correcting the workpiece surface by changing the finishing conditions of different areas according to the profile of the initial surface, such as feed speed. In previous research, the feasibility and effectiveness of this method were proven. In this research, a theoretical analysis of this method was carried out and the extension of this method to the processing of larger planes was studied. Through a series of experiments on an aluminum plate (A5052), it was proven that the shape accuracy of the workpiece surface can be effectively corrected by accurately controlling the feed speed. The experimental results showed that the extreme difference of the workpiece can be reduced from 4.81 μm to 2.65 μm within the processed area of 30 mm by 10 mm. Full article
(This article belongs to the Special Issue High Precision Abrasive Machining: Machines, Processes and Systems)
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Review

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29 pages, 8916 KiB  
Review
Precision Machining by Dicing Blades: A Systematic Review
by Zewei Yuan, Ali Riaz and Bilal shabbir Chohan
Machines 2023, 11(2), 259; https://doi.org/10.3390/machines11020259 - 09 Feb 2023
Cited by 5 | Viewed by 4928
Abstract
Diamond dicing blades are profound cutting tools that find their applications in semiconductor back-end packaging and assembly processes. To fully appreciate the benefits of the dicing blade technique for precision machining, a deeper understanding is required. This paper systematically reviews the contribution of [...] Read more.
Diamond dicing blades are profound cutting tools that find their applications in semiconductor back-end packaging and assembly processes. To fully appreciate the benefits of the dicing blade technique for precision machining, a deeper understanding is required. This paper systematically reviews the contribution of dicing blades in machining, followed by the context of dicing blades: production, characterization, methodology, and optimization. The readers are enlightened about the potential prospects that can be exploited for precision spectra as a result of current research and engineering developments. Full article
(This article belongs to the Special Issue High Precision Abrasive Machining: Machines, Processes and Systems)
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