Search Results (1,076)

Polymer-based superplasticizers represent an emerging class of additives in cement and concrete production with demonstrated effects on zeta potential, ion exchange, turbidity and rheological behavior during hydration. This study examines the influence of polymer-based grinding aids focusing on the dosage of A2 on the grinding performance of Portland cement. Among the tested additives, A2 exhibited superior dispersing ability and agglomeration-preventing activity, yielding a zeta potential of −8.98 mV. Correspondingly, the release of the ion concentration of Ca²⁺ decreased to 190 mg/L, while SO₄²⁻ increased to 400 mg/L, indicating enhanced ionic interaction at the optimal A2 dosage of 2.5 g. The turbidity tests further revealed that cement samples ground with 2.5 g of A2 remained homogeneously suspended for longer periods compared to other additives. Overall, the analysis of cement surface properties confirmed that polymer-based grinding aids, particularly A2, significantly improve the dispersion stability of cement particles during grinding. Full article

To investigate the influence of surface films on the material removal mechanism of single-crystal silicon during nanogrinding, molecular dynamics (MD) simulations were performed under different surface-film conditions. The simulations examined atomic displacements, grinding forces, radial distribution functions (RDF), phase transformations, temperature distributions, and residual stress distributions to elucidate the damage mechanisms at the surface and subsurface on the nanoscale. In this study, boron nitride (BN) and graphene films were applied to the surface of single-crystal silicon workpieces for nanogrinding simulations. The results reveal that both BN and graphene films effectively suppress chip formation, thereby improving the surface quality of the workpiece, with graphene showing a stronger inhibitory effect on atomic displacements. Both films reduce tangential forces and mitigate grinding force fluctuations, while increasing normal forces; the increase in normal force is smaller with BN. Although both films enlarge the subsurface damage layer (SDL) thickness and exhibit limited suppression of crystalline phase transformations, they help to alleviate surface stress release. In addition, the films reduce the surface and subsurface temperatures, with graphene yielding a lower temperature. Residual stresses beneath the abrasive grain are also reduced when either film is applied. Overall, BN and graphene films can enhance the machined surface quality, but further optimization is required to minimize subsurface damage (SSD), providing useful insights for the optimization of single-crystal silicon nanogrinding processes. Full article

This study addresses the challenges in machining the raceways and oil holes of aircraft engine bearing rings by conducting abrasive flow machining experiments on main bearing rings which had undergone ultra-precision grinding. Viscoelastic abrasive media containing cubic boron nitride of different particle sizes is used during the experiments. The results show that bearing performance is improved significantly in terms of surface roughness and residual compressive stress consequently; the overall surface quality is raised. The machining process meets the precision requirements for the main bearings of this type of aircraft engine, validating the feasibility and effectiveness of Abrasive Flow Machining (AFM), and the foundation for further optimization of this process is set through this research. Full article

During the grinding process of K9 glass, various forms of surface damage—such as indentations and pitting—as well as subsurface damage—including cracks and residual stress—are generated. This paper focuses on the planetary grinding method utilizing bonded abrasives for both process research and subsurface damage detection. It examines the timeliness of grinding duration and analyzes the effects of abrasive grain size and grinding pressure on surface quality. Building upon the principle of differential etching, an improved HF chemical etching method is proposed to establish a relationship model that correlates the depth of subsurface damage with abrasive grain size, applied pressure, and surface roughness. Full article

Waste materials have emerged as attractive low-cost feedstocks for adsorbent development in environmental remediation and materials engineering. Organic wastes are particularly rich in cellulose, hemicellulose, lignin, and pectin, which provide reactive oxygenated groups such as hydroxyls and carboxyls. While inorganic wastes offer stability, lower water retention makes them promising candidates. This study explores the functionalization of waste-derived organic and inorganic matrices using two amine-based agents: 3-aminopropyltrimethoxysilane (APTMS) and polyethylenimine (PEI). The materials were categorized as organic (orange peel, corn cob) or inorganic (silica gel, eggshell) and subjected to a pretreatment process involving drying, grinding, and sieving; inorganic substrates additionally underwent acid activation with citric acid. Surface modification was carried out in ethanolic (APTMS) or aqueous (PEI) media. To assess their suitability and processability as particulate sorbents, drying kinetics, physicochemical properties (FTIR, ζ-potential, pH, conductivity, Boehm titration), and flow characteristics (Carr and Hausner indices) were evaluated. The findings enable a comparative analysis of the functionalization efficiency and elucidate the relationship between substrate type (organic vs. inorganic) and its performance as a modified adsorbent. This approach advances the development of novel sorbent matrices for greenhouse gas mitigation while reinforcing circular economy principles through the valorization of low-cost, readily available waste materials. Full article

This study comprehensively discusses the effect of multiple material recycling (five recycling cycles with the same technological conditions: injection molding → grinding → drying → injection molding → …) of commercial polypropylene-glass fiber composites (PPGF) (PP + 10, 20 and 30 wt.% GF) on the performance of the grinding process and the granulometric characteristics of the obtained regrinds, as well as selected surface, mechanical and thermal properties of the composites. An increase in mass (E_m) and volume (E_v) grinding efficiency was confirmed, along with an increase in GF content in the composite and the number of recycling cycles. Both the GF additive and the number of recycling cycles contributed to the deterioration of the aesthetic qualities of the composites (darkening and reduction in gloss). Slight changes in the surface hardness of the test materials were observed as a function of the number of recycling cycles, from 3 to 4% after five recycling cycles. The adverse effect of multiple recycling on the mechanical and thermal properties of PP and PPGF composites has been confirmed. The occurrence and increase in carbonyl index (CI) values, as a function of multiples recycling, was confirmed for a composite containing 20 wt.% GF (CI in the range from 0.045 to 0.092) and for PPGF containing 30 wt.% GF (CI in the range from 0.193 to 0.272). The effect of multiple material recycling on the glass fiber structure in the tested composites was also investigated using scanning electron microscopy (SEM) and optical microscopy. The issues of grinding and changes in the surface properties of PPGF composites in multiple material recycling processes discussed in this article may constitute a source of practical knowledge that will contribute to increasing the use of this type of secondary composite in industrial plastics processing processes. Full article

The level of magnetic grinding technology determines the accuracy and efficiency of magnetic grinding on the inner surface of aircraft engine bend pipes. This article analyzes the optimization methods of magnetic grinding process parameters for the inner surface of aircraft engine bent pipes, such as the multiple regression prediction method, the response surface method, and the grey relational analysis method. It is pointed out that the current optimization methods for magnetic grinding technology on the inner surface of aircraft engine bent pipes do not consider the nonlinear characteristics between various grinding process parameters, resulting in defects such as low precision and efficiency of magnetic particle grinding technology. An optimization approach was proposed to accurately predict the optimal magnetic grinding process parameters for the inner surface of aircraft engine bent pipes, establish a nonlinear mapping relationship that reflects the roughness of the inner surface of the bent pipe and the main process parameters, optimize the BP neural network model based on the genetic algorithm, design magnetic grinding experiments on the inner surface of aircraft engine bend pipes, and explore the magnetic grinding process that is beneficial for improving the accuracy and efficiency of magnetic grinding on the inner surface of aircraft engine bend pipes. It can achieve efficient and accurate prediction of magnetic grinding of the inner surface of aircraft engine bend pipes. It provides a basis for the manufacturing and maintenance of high-precision aircraft engine bend pipes. Full article

Electric vehicle (EV) drivetrains operate at high rotational speeds, which makes the noise, vibration, and harshness (NVH) performance of gear transmissions a critical design factor. Without the masking effect of an internal combustion engine, gear whine can become a prominent source of passenger discomfort. This paper provides the first comprehensive review focused specifically on gear tooth surface waviness, a subtle manufacturing-induced deviation that can excite tonal noise. Periodic, micron-scale undulations caused by finishing processes such as grinding may generate non-meshing frequency “ghost orders,” leading to tonal complaints even in high-quality gears. The article compares finishing technologies including honing and superfinishing, showing their influence on waviness and acoustic behavior. It also summarizes modern waviness detection techniques, from single-flank rolling tests to optical scanning systems, and highlights data-driven predictive approaches using machine learning. Industrial case studies illustrate the practical challenges of managing waviness, while recent proposals such as controlled surface texturing are also discussed. The review identifies gaps in current research: (i) the lack of standardized waviness metrics for consistent comparison across studies; (ii) the limited validation of digital twin approaches against measured data; and (iii) the insufficient integration of machine learning with physics-based models. Addressing these gaps will be essential for linking surface finish specifications with NVH performance, reducing development costs, and improving passenger comfort in EV transmissions. Full article

Zirconia (ZrO₂) ceramics are advanced structural materials that exhibit exceptional performance in aerospace and other heavy-duty applications. Since conventional machining of ZrO₂ ceramics presents significant challenges, this study employs the longitudinal–torsional coupled rotary ultrasonic machining (LTC-RUM) method for end surface grinding of ZrO₂ ceramics. To elucidate the material removal mechanism of LTC-RUM, an analysis was conducted from the perspective of individual abrasive grains. Subsequently, LTC-RUM experiments were carried out on ZrO₂ ceramic samples to investigate the effects of processing parameters on cutting force, surface roughness, and surface morphology. The results show that cutting force decreases with lower spindle speed and ultrasonic power, but increases with higher feed rate and cutting depth. The surface roughness decreases with increasing spindle speed, yet increases with feed rate. Moreover, the surface roughness initially decreases and then increases with increasing ultrasonic power and cutting depth. Compared to conventional machining methods, LTC-RUM significantly reduces cutting force and surface roughness, thereby improving workpiece surface quality. This study provides valuable insights into the application of LTC-RUM for machining ZrO₂ ceramics and other hard and brittle materials. Full article

The roller press crushing of ore is a complex process involving the interplay of multiple factors. Roller dimensions, gap settings, and rotational speed all influence this process, which in turn affects the comprehensive crushing performance of the high-pressure grinding rolls (HPGR). Therefore, to simultaneously enhance the HPGR’s size reduction effectiveness (SRE) and throughput while controlling its energy consumption, wear, and edge effect, multi-objective parameter optimization of the HPGR is required. This study utilizes the Discrete Element Method (DEM) to simulate ore comminution within an HPGR. By first dividing the release zone into segments, the particle size distribution of the crushed product at different locations within this zone is investigated. Then, the influence of various factors on the SRE at different locations within HPGR is examined through single-factor experiments. Subsequently, the relative influence of roller diameter, roller width, roller speed, and roll gap on the comprehensive crushing performance of the HPGR is determined through signal-to-noise ratio (SNR) analysis and analysis of variance (ANOVA). Finally, multi-objective parameter optimization of the roller press crushing is conducted based on grey relational analysis (GRA), incorporating the weights assigned to different response target. The results indicate that the proportion of unbroken ore particles is relatively significant, primarily due to the edge effect. Further analysis reveals that along the horizontal diameter of the rollers, regions closer to the roller surface exhibit better SRE. Additionally, roller speed is identified as the most influential factor affecting the uniformity of SRE in the HPGR. The application of GRA to the multi-objective optimization of roller press crushing enables effective balancing of the comprehensive crushing performance in HPGR. Full article

To enhance the grinding performance and service life of rail grinding wheels, a novel brazed–resin composite wheel was developed by embedding brazed CBN (cubic boron nitride) segments into a resin working layer. The brazed CBN segments were fabricated using a Cu–Sn–Ti + WC (tungsten carbide) composite filler via a cold-press forming–vacuum brazing process. Microstructural and phase analyses revealed the formation of Ti–B and Ti–N compounds at the CBN–filler interface, indicating metallurgical bonding, while the incorporation of WC reduced excessive wetting, enabling precise shape retention of the segments. Comparative laboratory and field grinding tests were conducted against conventional resin-bonded wheels. Under all tested pressures, the composite wheel exhibited lower grinding temperatures, generated predominantly strip-shaped chips with lower oxygen content, and produced fewer spherical oxide-rich chips than the resin-bonded wheel, confirming reduced thermal load. Field tests demonstrated that the composite wheel matched the resin-bonded wheel in grinding efficiency, extended service life by approximately 28.8%, and achieved smoother rail surfaces free from burn-induced blue marks. These results indicate that the brazed–resin composite grinding wheel effectively leverages the superior hardness and thermal conductivity of CBN abrasives, offering improved thermal control, wear resistance, and surface quality in rail grinding applications. Full article

The cup-shaped grinding wheels with arc-shaped edges provide a satisfactory precision grinding solution for high-accuracy optical surfaces on hard and brittle materials. However, the complex profile of the arc-shaped edges of cup-shaped grinding wheels makes them challenging to truing. This paper proposes an on-machine truing technique targeting cup-shaped grinding wheels with arc-shaped cutting edge. First, a mathematical model was established to simulate the three-axis of on-machine truing the arc-shaped cutting edge using a diamond roller. Based on this model, a theoretical analysis is conducted to investigate the impact of tool setting errors, measurement errors of the diamond roller, and the pose error on truing accuracy. A compensation method was proposed, and experimental results validated its effectiveness. To investigate the grinding performance of cup-shaped grinding wheels after truing, a complex component is ground using a truing diamond grinding wheel. The experimental results demonstrate that this method enables precise on-machine truing of the arc-shaped edges of cup-shaped grinding wheels and is efficient. The average dimensional accuracy of the grinding wheel’s arc-shaped edge is reduced to 1.5 μm, with the profile accuracy (PV) of 0.89 μm. Full article

Reaction-bonded silicon carbide (RB-SiC) is a high-performance ceramic material known for its excellent mechanical, thermal, and chemical properties. It contains phases with different mechanical properties, which introduce complex machining mechanisms. In the present work, molecular dynamics (MD) simulation was conducted to investigate the effect of abrasive size on the nano-grinding mechanism of RB-SiC. The surface morphology and subsurface deformation mechanism were investigated. The simulation results suggest that when a small abrasive is used, the surface swelling of SiC is primarily generated by the bending and tearing of SiC at the interfaces. As the abrasive radius increases, the surface swelling is mainly formed by Si atoms, which is identified as elastic recovery. Meanwhile, the material removal rate gradually decreases, and the depth of plastic deformation is obviously increased. Stocking of Si is more apparent at the interface, and obvious sliding of SiC grains is observed, forming edge cracks at the margin of the workpiece. In the subsurface workpiece, the high-pressure phase transition (HPPT) of Si is promoted, and the squeeze of disordered Si is obvious with more dislocations formed when larger abrasive is used. Full article

In order to achieve the high-performance machining of silicon carbide (SiC) ceramics, longitudinal–torsional ultrasonic vibration (LTUV) was introduced into precision machining, and a systematic investigation into the effects of various process parameters on the critical cutting depth and surface quality was conducted. This investigation was undertaken with a view to exploring the ultrasonic vibration-assisted grinding mechanism of SiC ceramics. Firstly, the kinematic model of single abrasive grain trajectory and the maximum unaltered cutting thickness during longitudinal–torsional ultrasonic vibration-assisted grinding (LTUVG) was established to explore its unique grinding characteristics. On this basis, the theoretical modeling of critical cutting depth in SiC ceramics under LTUVG conditions was developed. This was then verified through longitudinal–torsional ultrasonic scratching (LTUS) experiments, and the theoretical analysis and test results prove that compared with normal scratching, the quality of SiC grooves are significantly improved by means of LTUS. During LTUS experiments, the dynamic fracture toughness, strain rate of SiC, and high-frequency ultrasonic excitation significantly enhances SiC performance, increasing the critical cutting depth and expanding the plastic removal region, so it is easy for LTUVG to yield the better surface quality in machined SiC ceramics, which provides important scholarly support for achieving the low-damage machining of SiC ceramics. Full article

Ultrasonic-assisted machining (UAM) has emerged as a transformative technology for increasing material removal efficiency, improving surface quality and extending tool life in precision manufacturing. This review specifically focuses on the application of it to titanium aluminide (TiAl) alloys. These alloys are widely used in aerospace and automotive sectors due to their low density, high strength and poor machinability. This review covers various aspects of UAM, including ultrasonic vibration-assisted turning (UVAT), milling (UVAM) and grinding (UVAG), with emphasis on their influence on the machinability, tool wear behavior and surface integrity. It also highlights the limitations of single-energy field UAM, such as inconsistent energy transmission and tool fatigue, leading to the increasing demand for multi-field techniques. Therefore, the advanced machining strategies, i.e., ultrasonic plasma oxidation-assisted grinding (UPOAG), protective coating-assisted cutting, and dual-field ultrasonic integration (e.g., ultrasonic-magnetic or ultrasonic-laser machining), were discussed in terms of their potential to further improve TiAl alloys processing. In addition, the importance of predictive force models in optimizing UAM processes was also highlighted, emphasizing the role of analytical and AI-driven simulations for better process control. Overall, this review underscores the ongoing evolution of UAM as a cornerstone of high-efficiency and precision manufacturing, while providing a comprehensive outlook on its current applications and future potential in machining TiAl alloys. Full article