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Nickel based super-alloys are widely employed in aircraft engines and gas turbines due to their high temperature strength, corrosion resistance and, excellent thermal fatigue properties. Conversely, these alloys are very difficult to machine and cause rapid wear of the cutting tool, frequent tool changes are thus required resulting in low economy of the machining process. This study provides a detailed review of the tool wear mechanism in the machining of nickel based super-alloys. Typical tool wear mechanisms found by different researchers are analyzed in order to find out the most prevalent wear mechanism affecting the tool life. The review of existing works has revealed interesting findings about the tool wear mechanisms in the machining of these alloys. Adhesion wear is found to be the main phenomenon leading to the cutting tool wear in this study.

High-speed machine tool working table restrains the machining accuracy and machining efficiency, so lightweight design of the table is an important issue. In nature, leaf has developed a plate structure that maximizes the surface-to-volume ratio. It can be seen as a plate structure stiffened by veins. Compared with a high-speed machine tool working table, leaf veins play a role of supporting part which is similar to that of stiffening ribs, and they can provide some new design ideas for lightweight design of the table. In this paper, distribution rules of leaf veins were investigated, and a structural bionic design for the table was achieved based on regulation of leaf veins. First, statistical analysis on geometric structure of leaf veins was carried out, and four distribution rules were obtained. Then, relevant mechanical models were developed and analyzed in finite element software. Based on the results from mechanical analysis on those relevant models, the four distribution rules were translated into the design rules and a structural bionic design for the working table was achieved. Both simulation and experimental verifications were carried out, and results showed that the average displacement of the working table was reduced by about 33.9%.

The lightweight and high efficiency of natural structures are the inexhaustible sources for engineering improvements. The goal of the study is to find innovative solutions for mechanical lightweight design through the application of structural bionic approaches. Giant waterlily leaf ribs and cactus stem are investigated for their optimal framework and superior performance. Their structural characteristics are extracted and used in the bio-inspired design of Lin MC6000 gantry machining center crossbeam. By mimicking analogous network structure, the bionic model is established, which has better load-carrying capacity than conventional distribution. Finite Element Method (FEM) is used for numerical simulation. Results show better specific stiffness of the bionic model, which is increased by 17.36%. Finally the scaled models are fabricated by precision casting for static and dynamic tests. The physical experiments are compared to numerical simulation. The results show that the maximum static deformation of the bionic model is reduced by about 16.22%, with 3.31% weight reduction. In addition, the first four natural frequencies are improved obviously. The structural bionic design is a valuable reference for updating conventional mechanical structures with better performance and less material consumption.

High load-bearing efficiency is one of the advantages of biological structures after the evolution of billions of years. Biomimicking from nature may offer the potential for lightweight design. In the viewpoint of mechanics properties, the culm of bamboo comprises of two types of cells and the number of the vascular bundles takes a gradient of distribution. A three-point bending test was carried out to measure the elastic modulus. Results show that the elastic modulus of bamboo decreases gradually from the periphery towards the centre. Based on the structural characteristics of bamboo, a bionic cylindrical structure was designed to mimic the gradient distribution of vascular bundles and parenchyma cells. The buckling resistance of the bionic structure was compared with that of a traditional shell of equal mass under axial pressure by finite element simulations. Results show that the load-bearing capacity of bionic shell is increased by 124.8%. The buckling mode of bionic structure is global buckling while that of the conventional shell is local buckling.

Based on the configuration principles of biological skeletons and sandwich stems, a machine tool column with stiffening ribs inside was designed using structural bionic method. After the lightening effect was verified by finite element simulation, scale-down models of a conventional column and a bionic column were fabricated and tested. Results indicate that the bionic column can reduce the maximum static displacement by 45.9% with 6.13% mass reduction and its dynamic performances is also better with increases in the first two natural frequencies. The structural bionic design is effective in improving the static and dynamic structural performances of high speed machine tools.