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Abstract Surface design by tailoring topographical features and interface function groups to modulate dynamic or kinetic behaviors of liquid droplets, has been an increasing hotspot due to its broad spectrum of applications in biochemical diagnosis, microfabrication, and energy conversion systems. Here we report an engineered surface decorated by packed nanosized caltrops resulting from two perfectly articulated oxidation processes, where self-assembled nanoislands generated in the 1st plasma oxidation serve as protective masks in the 2nd chemical oxidation. As caltrops per design can effectively block lateral motion, the present surface can anchor contact lines of advancing water films when being hydrophilic and selectively capture impinging droplets when being hydrophobic. Furthermore, biphilic patterns can be readily obtained by integrating nanocaltrops with other surface asperities, engendering directional droplet maneuvering and designated droplet arraying. This work provides guidelines in designing nanostructures that achieve on-demand manipulation of droplets and flow patterns for multifunctional applications.

Abstract Background A knowledge of gouty arthritis could help in the primary prevention of the disease development and lead to an early diagnosis if it occurs. This study investigated the knowledge, attitudes, and practices (KAP) toward gouty arthritis in the general population > 30 years old. Methods This web-based cross-sectional study was conducted among the general population > 30 years old between January and March 2023 in Chengdu, Sichuan. The questionnaire was designed by the investigators based on the available guidelines (Cronbach’s α = 0.846). A score above 70% indicated good knowledge, a positive attitude, and proactive practice. Multivariable and structural equation modeling (SEM) analyses were performed to analyze the factors influencing KAP. Results A total of 537 questionnaires were included. The knowledge, attitudes, and practices scores were 13.12 ± 6.41, 25.28 ± 3.97, and 45.25 ± 5.77, respectively. Female (OR = 0.47, 95%CI: 0.31–0.71, P 10,000 yuan (OR = 2.07, 95%CI: 1.12–3.81, P = 0.020) were independently associated with attitudes. Attitude (OR = 1.31, 95%CI: 1.23–1.40, P

Summary: Mesoscale to nanoscale three-dimensional (3D) fabrication mostly requires complicated industry processing techniques. Here, we present a protocol for 3D shaping control by solidifying a water-based TiO2 nanofluid drop on a polygonal wettability-patterned surface. We detail the steps for preparing stable TiO2 nanofluid and wettability-patterned surfaces. We then describe the experimental procedure to obtain various and precise 3D morphologies by adjusting the deposited TiO2 nanofluid drop volume. This protocol provides a promising technique for future 3D manufacturing.For complete details on the use and execution of this protocol, please refer to Jiang et al.1 : Publisher’s note: Undertaking any experimental protocol requires adherence to local institutional guidelines for laboratory safety and ethics.

To solve the problems of poor surface quality and low tool life in conventional machining (CM) of AerMet100 steel, an experimental study was conducted in laser-assisted machining (LAM) of AerMet100 steel. The effects of laser power, cutting speed, feed rate, and depth of cut on the surface roughness of AerMet100 steel were studied based on a single-factor experiment. The degree of influence of each factor on the surface roughness was evaluated by analyses of variance and range in the orthogonal experiment, and the combination of process parameters for the optimal surface roughness was obtained. The order of influence was as follows: laser power > cutting speed > depth of cut > feed rate; the optimal combination of process parameters was laser power 200 W, cutting speed 56.5 m/min, feed rate 0.018 mm/rev, and depth of cut 0.3 mm. Compared to CM, the surface morphology of the workpiece under the optimization of LAM was relatively smooth and flat, the surface roughness Ra was 0.402 μm, which was reduced by 62.11%, the flank wear was reduced from 208.69 μm to 52.17 μm, there were no tipping or notches, and the tool life was significantly improved. The study shows that the LAM of AerMet100 steel has obvious advantages in improving surface quality and reducing tool wear.

Magnetic abrasive finishing (MAF) is an efficient finishing process method using magnetic abrasive particles (MAPs) as finishing tools. In this study, two iron-based alumina magnetic abrasives with different particle size ranges were synthesized by the plasma molten metal powder and powder jetting method. Characterization of the magnetic abrasives in terms of microscopic morphology, phase composition, magnetic permeability, particle size distribution, and abrasive ability shows that the magnetic abrasives are spherical in shape, that the hard abrasives are combined in the surface layer of the iron matrix and remain sharp, and that the hard abrasives combined in the surface layer of the magnetic abrasives with smaller particle sizes are sparser than those of the magnetic abrasives with larger particle sizes. The magnetic abrasives are composed of α-Fe and Al2O3; the magnetic permeability of the magnetic abrasives having smaller particle sizes is slightly higher than that of the magnetic abrasives having larger particle sizes; the two magnetic abrasives are distributed in a range of different particle sizes; the magnetic abrasives have different magnetic permeabilities, which are higher than those of the larger ones; both magnetic abrasives are distributed in the range of smaller particle sizes; and AZ31B alloy can obtain smaller surface roughness of the workpiece after the grinding process of the magnetic abrasives with a small particle size.

Although magnetic abrasive finishing (MAF) is an efficient surface finishing technique, its promotion and use in the precise polishing of high-hardness objects are constrained by the poor finishing performance and short service life of magnetic abrasive powders (MAPs). In this study, a double-stage atomization technique is employed to successfully manufacture MAPs with a polycrystalline diamond (PCD) as an abrasive phase. Analysis was performed on the graphitization of PCD abrasive and the circularity of the created MAPs as a result of cooling temperature. Therefore, the pressure ranges of the first-stage atomizer are suggested based on the theoretically designed kinetic model of PCD abrasives' penetration behavior into liquid metal. As revealed in the preparation experiment findings, PCD abrasives with their original crystal structure were deeply embedded on the surface of a spherical iron matrix. The generated PCD MAPs with smaller particle sizes exhibited better soft magnetic characteristics due to the atomization process’ quick cooling. The MAF results implied that PCD MAPs curtailed the roughness of cemented carbide from 302 nm to 85.2 nm, and their service life exceeds 60 min. The findings of this research can provide technical assistance for the creation of high-performance PCD MAPs.

Due to the excellent properties of carbon fiber-reinforced polymers (CFRPs), such as high strength and strong corrosion resistance, the traditional water-jet-guided laser (WJGL) technology has problems with fiber pull-out and has a small cutting depth when processing CFRPs. Therefore, in this study, we used high-power water-jet-guided laser (HPWJGL) technology to perform groove processing experiments on CFRPs. The effects of four key process parameters, high laser power, pulse frequency, feed rate, and water-jet pressure, on the cutting depth were investigated by a single-factor experiment. The formation mechanism of groove cross-section morphology and the processing advantages of high-power water-jet-guided lasers were analyzed. On this basis, the mathematical prediction model of cutting depth was established by using the response surface method (RSM), and the optimal combination of process parameters was obtained. The mathematical prediction model was verified by experiments, and the error was only 1.84%, indicating that the model had a high reference value. This study provides a reference for the precision machining of HPWJGL technology.

In order to automatically process ultra-fine copper tube electrodes, this study proposes a new method of ultrasonic vibration processing of ultra-fine copper tube, analyzes its processing principle, designs a new set of experimental processing equipment and completes the processing of 1.206 mm inner diameter, 1.276 mm outer diameter with core brass tube. Not only can the copper tube be completed with core decoring, the surface of the processed brass tube electrode also has good integrity. The effect of each machining parameter on the surface roughness of the electrode after machining was investigated by a single-factor experiment and the optimal machining effect was achieved under the conditions of machining gap 0.1 mm, ultrasonic amplitude 0.186 mm, table feed speed 6 mm/min, tube rotation speed 1000 r/min and reciprocating machining two times. The surface roughness was reduced from 1.21 μm before machining to 0.11 μm, and the residual pits, scratches and oxide layer on the surface were completely removed, which greatly improved the surface quality of the brass tube electrode and prolonged its service life.

Icing in the form of condensation frosting occurs ubiquitously in our daily life and numerous industrial applications. As the frost layer mostly comprises mixed microscopic dendrites and discrete air pockets, condensation frosting manifests a thick porous media and thus catastrophically compromises the heat transfer efficiency of HVAC systems. Despite being a popular research topic for centuries, a few unprecedented advances in the study of condensation frosting have been only achieved very recently, such as the revealing of new features in the incipient stages of frost formation, which used to be too fast or too small to capture, and new anti-/de-frosting techniques have been developed based on the revealed physics. This work provides a comprehensive, up-to-date review of condensation frosting, with an emphasis placed on progress in the very latest decade. Fundamentals of condensation frosting, including condensation nucleation, coalescence and growth of the condensed drops, icing nucleation, formation of frost halos, freezing propagation via ice bridging, and lastly densification and fully developed frost layers, are introduced chronologically as what occurs. A summary of recent engineering efforts to alleviate the negative impacts of condensation frosting, referred to as anti-/de-frosting techniques, is also presented. The results of these studies can greatly enlighten the existing understanding of condensation frosting and, meanwhile, benefit the development of new anti-/de- frosting methods for numerous application backgrounds.

Various numerical schemes of contact angle are widely used in pseudopotential lattice Boltzmann model to simulate substrate contact angle in condensation. In this study, effects of numerical schemes of contact angle on condensation nucleation and heat transfer simulation are clarified for the first time. The three numerical schemes are pseudopotential-based contact angle scheme, pseudopotential-based contact angle scheme with a ghost fluid layer constructed on the substrate with weighted average density of surrounding fluid nodes, and the geometric formulation scheme. It is found that the subcooling condition destabilizes algorithm of pseudopotential-based contact angle scheme. However, with a ghost fluid layer constructed on the substrate or using geometric formulation scheme, the algorithm becomes stable. The subcooling condition also decreases the simulated contact angle magnitude compared with that under an isothermal condition. The fluid density variation near a microcavity wall simulated by pseudopotential-based contact angle scheme plays the role of the condensation nucleus and triggers “condensation nucleation”. However, with a ghost fluid layer constructed on the substrate or using geometric formulation scheme, the simulated fluid density distribution near the wall is uniform so that no condensation nucleus appears in the microcavity. Thus, “condensation nucleation” cannot occur spontaneously in the microcavity unless a thin liquid film is initialized as a nucleus in the microcavity. The heat flux at the microcavity wall is unphysical during the “condensation nucleation” process, but it becomes reasonable with a liquid film formed in the microcavity. As a whole, it is recommended to use pseudopotential-based contact angle scheme with a ghost fluid layer constructed on the substrate or use the geometric formulation scheme to simulate condensation under subcooling conditions. This study provides guidelines for choosing the desirable numerical schemes of contact angle in condensation simulation by pseudopotential lattice Boltzmann model so that more efficient strategies for condensation heat transfer enhancement can be obtained from numerical simulations.

Evaporation of a sessile drop is ubiquitous in nature and has many industrial applications. Despite extensive studies over recent decades, a critical issue, i.e., how temperature varies near contact lines, remains elusive. In this work, we report to date the first direct experimental measurement showing the microscopic temperature distribution near contact lines of an evaporating pinned sessile drop. Using a fluorescence-based thermometry, we find that the temperature at the free interface near contact lines varies drastically along the radial direction, engendering a concentric fringe pattern that evolves over the evaporation lifespan. The formation of such fringe patterns is attributed to a combined mechanism of locally enhanced evaporative cooling at the drop edge and the development of interfacial convective vortices due to Bénard-Marangoni instability. We also study the evaporation dynamics at different initial contact angles and find that the characteristics of this fringe pattern vary as the initial contact angle decreases. Our experimental investigation and theoretical analysis in this work reveal insights to the understanding of droplet evaporation dynamics in various heat transfer systems.

In this investigation, spherical Al2O3 magnetic abrasive particles (MAPs) were used to polish the inner surface of ultra-fine long cobalt–chromium alloy cardiovascular stent tubes. The magnetic abrasives were prepared by combining plasma molten metal powder and hard abrasives, and the magnetic abrasives prepared by this new method are characterized by high sphericity, narrow particle size distribution range, long life, and good economic value. Firstly, the spherical Al2O3 magnetic abrasives were prepared by the new method; secondly, the polishing machine for the inner surface of the ultra-fine long cardiovascular stent tubes was developed; finally, the influence laws of spindle speed, magnetic pole speed, MAP filling quantities, the magnetic pole gap on the surface roughness (Ra), and the removal thickness (RT) of tubes were investigated. The results showed that the prepared Al2O3 magnetic abrasives were spherical in shape, and their superficial layer was tightly bound with Al2O3 hard abrasives with sharp cutting; the use of spherical Al2O3 magnetic abrasives could achieve the polishing of the inner surface of ultra-fine cobalt–chromium alloy cardiovascular bracket tubes, and after processing, the inner surface roughness (Ra) of the tubes decreased from 0.337 µm to 0.09 µm and had an RT of 5.106 µm.

In this study, the water-jet-guided laser (WJGL) method was used to cut Inconel 718 alloy with high temperature resistance. The effect of critical parameters of the water-jet-guided laser machining method on the cutting depth was studied by a Taguchi orthogonal experiment. Furthermore, the mathematical prediction model of cutting depth was established by the response surface method (RSM). The validation experiments showed that the mathematical model had a high predictive ability for cutting depth. The optimal cutting depth was obtained by model prediction, and the error was 5.5% compared with the experimental results. Compared with the traditional dry laser cutting, the water conducting laser method reduced the thermal damage and improved the cutting quality. This study provides a reference for the precision machining of Inconel 718 with a water-jet-guided laser.

This paper describes the application of bonded magnetic abrasive powders (MAPs) in the magnetic abrasive finishing (MAF) process. In order to improve the poor finishing performance and short service life of MAPs in polishing super-hard materials, a double-stage atomization technique was used to successfully manufacture MAPs with a CBN as an abrasive phase. The prepared results show that CBN abrasives with their original structure were deeply and densely embedded on the surface of spherical MAPs. Based on the MAF process, a five-level and four-factor central composite design experiment was carried out to verify the developed MAPs polishing performance on the finishing of cemented carbide parts (864 Hv). Working gap, rotational speed, feed rate of a workpiece, and mesh number of MAP were considered as influence factors. The analysis data was used to understand different interactions of significant parameters. A regression model for predicting the change of surface roughness was obtained, and the optimal parameter combination was figured out through a solution of a quadratic equation in Design-Expert software. According to MAF results, the strong cutting ability of atomized CBN MAPs improved the surface roughness of cemented carbide by over 80% at the optimum parameters. The strong cutting ability of atomized CBN MAPs can produce good surface quality on the hard materials. The findings of this research can promote a large-scale application of MAF technology in the surface polishing of hard materials.

In this paper, the surface roughness of SiC ceramics was investigated in laser-assisted machining (LAM) processes; machine learning was used to predict surface roughness and to optimize the process parameters, and therefore, to ultimately improve the surface quality of a workpiece and obtain excellent serviceability. First, single-factor turning experiments were carried out on SiC ceramics using LAM according to the material removal mechanism to investigate the variation trend of the effects of different laser powers, rotational speeds, feed rates, and cutting depths on surface roughness. Then, laser power, rotational speed, feed rate and cutting depth were selected as the four factors, and the surface roughness was used as the target value for the orthogonal experiments. The results of the single-factor experiments and the orthogonal experiments were combined to construct a prediction model based on the combination of the grey wolf optimization (GWO) algorithm and support vector regression (SVR). The coefficient of determination (R2) of the optimized prediction model reached 0.98676 with an average relative error of less than 2.624%. Finally, the GWO algorithm was used to optimize the global parameters of the prediction model again, and the optimal combination of process parameters was determined and verified by experiments. The actual minimum surface roughness (Ra) value was 0.418 μm, and the relative error was less than 1.91% as compared with the predicted value of the model. Therefore, the prediction model based on GWO-SVR can achieve accurate prediction of the surface roughness of SiC ceramics in LAM and can obtain the optimum surface roughness using parameter optimization.

High-performance iron-based Al2O3 magnetic abrasive powder (MAP) prepared by combining plasma molten metal powder with sprayed abrasive powder is used for magnetic abrasive finishing (MAF) of AZ31B magnesium alloy to remove surface defects such as creases, cracks, scratches, and pits generated during the manufacturing process of the workpiece, and to reduce surface roughness and improve its wear and corrosion resistance. In order to solve the problem of magnetic abrasive powder splash in the MAF process, the force analysis of the MAP in the processing area is conducted, and a composite magnetic pole processing device was designed and simulated to compare the effects of both devices on MAF, confirming the feasibility of composite magnetic pole grinding. Then, experiments have been designed using Response Surface Methodology (RSM) to investigate the effect of four factors-magnetic pole rotation speed, grinding gap, magnetic pole feed rate, magnetic abrasive filling quantity-on surface roughness and the interactions between them. The minimum surface roughness value that can be obtained is used as the index for parameter optimization, and the optimized parameters are used for experiments, and the results show that the established surface roughness model has good predictive ability.

Due to the special manufacturing process of cobalt–chromium alloy cardiovascular stent tubes, there are serious surface defects in their inner walls, which affects the therapeutic effect after implantation. At the same time, the traditional processing technology cannot finish the inner wall of a cardiovascular stent tube. In light of the above problems, magnetic abrasive finishing (MAF) equipment for the inner wall of an ultra-fine and ultra-long cardiovascular stent tube is proposed, and MAF technology is used to improve the surface quality of its inner wall. High-performance spherical magnetic abrasive powders are used to finish the inner wall of a cobalt–chromium alloy cardiovascular stent tube with an inner diameter of 1.6 mm and an outer diameter of 1.8 mm. The effects of finishing time, tube rotational speed, feed speed of the magnetic pole, MAPs filling quantity, and MAP abrasive size on the surface roughness and material removal thickness of cobalt–chromium alloy cardiovascular stent tube are investigated. The results show that the surface roughness of the inner wall of the cobalt–chromium alloy cardiovascular stent decreases from 0.485 μm to 0.101 μm, and the material removal thickness of the defect layer is 4.3 μm. MAF technology is used to solve the problem of the poor surface quality of the inner walls of ultra-fine and ultra-long cobalt–chromium alloy cardiovascular stent tubes.

In this study, a new method of ultrasonic high-frequency percussion (UH-FP) is proposed. Ultra-fine and ultra-long copper tube electrodes cannot be fabricated by traditional processing methods, and the copper tube electrodes fabricated by UH-FP can be used in the process of rotary EDM for microfine holes. The UH-FP setup has been established based on an ultrasonic device, a workpiece chucking and rotation device, and a workpiece reciprocating motion device. In this work, by studying the principle of ultrasonic processing, the processing principle and mechanism of ultra-fine and ultra-long copper tube electrode preparation by ultrasonic high-frequency percussion is proposed. The effects of processing parameters (i.e., rotational speed, feed rate, working gap, percussion amplitude) on surface roughness are evaluated quantitatively. Experimental results show that the proposed method could complete the core leach of the core-containing copper tube electrodes after drawing, while improving surface quality. Some surface defects such as cracks, scratches and folds were completed removed, further improving the mechanical performance of processed parts. The surface roughness (Ra) of 0.091 μm was obtained from the initial 0.46 μm under the optimal processing parameters of 800 rpm tube rotational speed, 200 mm/min platform feed speed, 0.13 mm machining gap, 0.15 mm percussion amplitude, and 32 min machining time. The method shows potential for manufacturing copper tube electrodes for a wide range of industrial applications.

Fused silica is an important optical material with important applications, where the surface must be precisely machined without subsurface damage. In this study, multi-cyclic indentations under incremental loads were performed on fused silica using two kinds of indenters to clarify the mechanisms of crack generation and propagation induced by precision grinding. It was found that incremental loading cyclic nanoindentation induced various patterns of subsurface cracking and surface spalling. Four kinds of surface spalling were identified at different locations around an indent, the temporal formation mechanisms of which were clarified by microscopic observation and topographical measurement. Load–displacement curve analysis demonstrated that incremental propagation of lateral cracks during early indentation cycles caused large-scale brittle fractures during later cycles. Compared with a Berkovich indenter, a cube-corner indenter caused more significant brittle fractures and surface spalling. The findings in this study will deepen the understanding of subsurface damaging mechanism of fused silica and other brittle solids caused by cyclic tool-workpiece interactions in grinding and other mechanical machining processes.

Laser cleaning technology has the advantages of being green and efficient and is expected to become the most promising remanufacturing cleaning technology. However, the quasi-continuous laser can easily cause problems, such as a heat-affected zone and a recast layer on the substrate material, which limits the development of laser cleaning technology. The environmentally friendly water jet-guided quasi-continuous laser proposed in this paper is an innovative laser cleaning technology that can remove the resin-based coating on the metal substrate with high quality. The epoxy resin coating on the 304 stainless steel surface was cleaned by a water jet guided quasi continuous laser, and the surface morphology, surface element content, and surface roughness of the cleaning area were tested and analyzed. The removal mechanism of water jet-guided quasi-continuous laser cleaning technology was revealed, and the influence of process parameters on cleaning surface quality was found. The optimal process parameters were as follows: the energy density of the water jet-guided laser 17.5 J/cm2, the cleaning speed 135 mm/s, the cleaning line spacing 0.1 mm, and the laser pulse frequency 900 Hz. Therefore, this study is expected to be an important basis for water jet-guided quasi-continuous laser cleaning technology, and promote the development of water jet-guided laser cleaning technology.

Condensation frosting is a type of icing encountered ubiquitously in our daily lives. Understanding the dynamics of condensation frosting is essential in developing effective technologies to suppress frost accretions that compromise heat transfer and system integrity. Here, we present an experimental study on ice dendrite growth atop a single frozen drop, an important step affecting the subsequent frosting process, and the properties of fully-developed frost layers. We evaluate the effect of natural convection by comparing the growth dynamics of ice dendrites on the surface of a frozen drop with three different orientations with respect to gravity. The results show that both the average deposition rate and its spatial variations are profoundly altered by surface orientations. Such behavior is confirmed by a numerical simulation, showing how gravity-assisted (hindered) vapor diffusion yields the deposition outcomes. These findings benefit the optimization of anti-/de- frosting technologies and the rational design of heat exchangers.

Carbon nanofibers (CNFs) have various excellent properties, such as high tensile strength, electric conductivity and current density resistance, and thus have great application potential in electrical sensor development. In this research, electrically conductive composite elements using CNFs sandwiched by thermoplastic olefin (TPO) substrates were developed by press molding. The metal mold used for press molding was processed by a femtosecond laser to generate laser-induced periodic surface structures (LIPSS) on the mold surface. The aggregate of CNFs was then flexibly fixed by the LIPSSs imprinted on the TPO substrate surface to produce a wavy conductive path of CNFs. The developed composite elements exhibited a sharp increase in electrical resistance as strain increased. A high gauge factor of over 47 was achieved, which demonstrates high sensitivity against strain when the composite element is used as a strain gauge. Scanning electron microscope observation revealed that the TPO filled the spaces in the aggregate of CNFs after press molding, and the conductive path was extended by the tensile strain. The strain-induced dynamic changes of contact states of CNFs and CNFs networks are discussed based on the electrical performance measurement and cross-sectional observation of the elements. This research provides a new approach to the production of flexible and high sensitivity strain sensors.

Icing/snowing/frosting is ubiquitous in nature and industrial processes, and the accretion of ice mostly leads to catastrophic consequences. The existing understanding of icing is still limited, particularly for aircraft icing, where direct observation of the freezing dynamics is inaccessible. In this work, we investigate experimentally the impact and freezing of a water drop onto the supercooled substrate at extremely low vapor pressure, to mimic an aircraft passing through clouds at a relatively high altitude, engendering icing upon collisions with pendant drops. Special attention is focused on the ice coverage induced by an impinging drop, from the perimeter pointing outward along the radial direction. We observed two freezing regimes: (I) spread-recoil-freeze at the substrate temperature of Ts = −15.4 ± 0.2 °C and (II) spread (incomplete)-freeze at the substrate temperature of Ts = −22.1 ± 0.2 °C. The ice coverage is approximately one order of magnitude larger than the frozen drop itself, and counterintuitively, larger supercooling yields smaller ice coverage in the range of interest. We attribute the variation of ice coverage to the kinetics of vapor diffusion in the two regimes. This fundamental understanding benefits the design of new anti-icing technologies for aircraft.

In order to understand the work hardening phenomenon and mechanism of laser-assisted machining (LAM) of Si3N4 ceramics, the work hardening degree of LAM Si3N4 under different material removal modes was studied. Two sets of single-factor experiments were performed in which the laser power and the cutting depth were changed respectively. The results show that work hardening is the result of the combination of heat and cutting deformation during cutting. The work hardening degree decreases with the increase of material softening degree. When the material is removed plastically, the work hardening degree is 110−115%.

Energy conservation and emission reduction is an essential consideration in sustainable manufacturing. However, the traditional optimization of cutting parameters mostly focuses on machining cost, surface quality, and cutting force, ignoring the influence of cutting parameters on energy consumption in cutting process. This paper presents a multi-objective optimization method of cutting parameters based on grey relational analysis and response surface methodology (RSM), which is applied to turn AISI 304 austenitic stainless steel in order to improve cutting quality and production rate while reducing energy consumption. Firstly, Taguchi method was used to design the turning experiments. Secondly, the multi-objective optimization problem was converted into a simple objective optimization problem through grey relational analysis. Finally, the regression model based on RSM for grey relational grade was developed and the optimal combination of turning parameters (ap = 2.2 mm, f = 0.15 mm/rev, and v = 90 m/s) was determined. Compared with the initial turning parameters, surface roughness (Ra) decreases 66.90%, material removal rate (MRR) increases 8.82%, and specific energy consumption (SEC) simultaneously decreases 81.46%. As such, the proposed optimization method realizes the trade-offs between cutting quality, production rate and energy consumption, and may provide useful guides on turning parameters formulation.

There are high cutting temperatures, large tool wear, and poor tool life in conventional machining, owing to the superior strength and low thermal conductivity of titanium alloy. In this work, ultrasonic atomization assisted turning (UAAT) of Ti6Al4V was performed with a mixed water-soluble oil-based cutting fluid, dispersed into tiny droplets by the high frequency vibration of a piezoelectric crystal. Different cutting speeds and two machining environments, dry and ultrasonic atomization assisted machining, were considered in the investigation of tool life, tool wear morphology, surface roughness, and chip morphology. In comparison with dry machining, UAAT shows lower tool wear and longer tool life due to the advantages of cooling and lubrication. Furthermore, better surface roughness, smoother chip edges, and shorter tool-chip contact length were obtained with UAAT.

A superhydrophobic surface with low adhesion and good wear resistance was fabricated on Ti6Al4V substrates via TiO2/Ni composite electrodeposition, and subsequently modified with a fluoroalkylsilane (FAS) film. Scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and optical contact angle measurements were used to characterize the surface morphologies, chemical compositions, and surface wettability. The superhydrophobicity of the as-prepared surface results from the fabrication of a hierarchical structure and the assembly of low-surface energy fluorinated components. The as-prepared surface had a water contact angle as high as 162.6° and a sliding angle close to 1.8°. Scratch and abrasion tests showed that the superhydrophobic coating provided a superior wear resistance and stable mechanical abrasion protection. In addition, the influence of processing conditions, such as working voltage, deposited time, pH value, and TiO2 concentration, was also investigated.

Vehicles commonly suffer from the narrow-band noises and vibrations, usually a superposition of multiple sinusoidal signals, due to the excitations of engines, electrical motors, gear boxes, and other rotating mechanical parts. These excitations are transmitted to a reference point of some structure with certain transmission paths. The vibration signal measured at the reference point can be used for power system monitoring, fault diagnosis, modal analysis, noise analysis, etc. For convenience, researchers in a laboratory usually use shakers to generate expected narrow-band vibration signals acting on the vehicle structure reference points to simulate the vibration signals. However, there is a prominent difficulty in ensuring the amplitude and phase accuracy of each sub-frequency component simultaneously. In order to improve the accuracy of generating the expected vibration signal, this paper presents a multi-source vibration simulation control technology based on the tracking filter method. The main idea is to use the tracking filter to estimate the amplitude and phase of the target sub-frequency component accurately. Further, on the target sub-frequency, the drive signal of shakers is then corrected based on the amplitude and phase errors to achieve a more accurate target vibration signal. The amplitude and phase of each sub-frequency component in the excitation signal can be controlled independently. Compared with other Fast Fourier Transform (FFT)-based frequency domain analysis algorithms and numerical methods by solving the equations, the tracking filter method has a higher frequency resolution and higher accuracy. It can be easily realized in real time applications due to its simplicity. Finally, verification experiments are completed. The experimental results show that the multi-source vibration simulation control technology presented in this paper can achieve high-precision amplitude and phase on each sub-frequency component of the target vibration signals, which contain up to eight sub-frequency components.