Compared to conventional machining (CM), ultrasonic vibration-assisted machining (UVAM) with high-frequency and small-amplitude has exhibited good cutting performances for advanced materials. In recent years, advances in ultrasonic generator, ultrasonic transducer, and horn structures have led to the rapid progress in the development of UVAM. Following this trend, numerous new design requirements and theoretical concepts have been proposed and studied successively, however, very few studies have been conducted from a comprehensive perspective. To address this gap in the literature and understanding the development trend of UVAM, a critical overview of UVAM is presented in this study, covering different vibration-assisted machining styles, device architectures, and theoretical analysis. This overview covers the evolution of typical hardware systems used to achieve vibratory motions from the one-dimensional UVAM to three-dimensional UVAM, the discussion of cutting characteristics with periodic separation between the tools and workpiece and the analysis of processing properties. Challenges for UVAM include ultrasonic vibration systems with high power, large amplitude, and high efficiency, as well as theoretical research on the dynamics and cutting characteristics of UVAM. Consequently, based on the current limitations and challenges, device improvement and theoretical breakthrough play a significant role in future research on UVAM.

Review of ultrasonic vibration-assisted machining in advanced materials

从内容编排、栏目设置、插图与版式设计等几个角度对美国普通化学教材Chemistry：The Molecular Nature of Matter and Change的编写特色进行评析，以期对我国同类教材的编写提供参考。

Chemistry:The Molecular Nature of Matter and Change评述

The paper describes the state-of-the-art in replication of surface texture and topography at micro and nano scale. The description includes replication of surfaces in polymers, metals and glass. Three different main technological areas enabled by surface replication processes are presented: manufacture of net-shape micro/nano surfaces, tooling (i.e. master making), and surface quality control (metrology, inspection). Replication processes and methods as well as the metrology of surfaces to determine the degree of replication are presented and classified. Examples from various application areas are given including replication for surface texture measurements, surface roughness standards, manufacture of micro and nano structured functional surfaces, replicated surfaces for optical applications (e.g. optical gratings), and process chains based on combinations of repeated surface replication steps.

Replication of micro and nano surface geometries

Micro-structured functional surfaces have achieved widespread applications in various advanced scientific, technological, industrial, and engineered fields due to their excellent performances, which are vitally limited by their feasible fabrication. Currently, ultra-precision machining, typically including ultra-precision diamond turning, ultra-precision diamond milling, ultra-precision diamond scratching, ultra-precision grinding, and ultra-precision polishing, is developed as a very-promising solution for the micro-structured functional surface fabrication with high quality, high efficiency, high flexibility, and low cost. Therefore, this paper aims to briefly review the current state of the art in the investigation into ultra-precision machining characteristics of micro-structured functional surfaces with a focus on their typical advanced applications as the significant achievements of their ultra-precision machining fabrication, discuss the key challenges, and further provide new insights into ultra-precision machining of micro-structured functional surfaces for the future research and their further advanced applications.

Advances in ultra-precision machining of micro-structured functional surfaces and their typical applications

http://www.yan.mech.keio.ac.jp/wp-site/wp-content/uploads/5Precision-machining-of-microstructures-on-electroless-plated-NiP-surface-for-molding-glass-components.pdf

Precision machining of microstructures on electroless-plated NiP surface for molding glass components

Glass molding is as an effective approach to produce precision micro optical elements with complex shapes at high production efficiency. Since glass is deformed at a high temperature where the mechanical and optical properties depend strongly on temperature, modeling the heat transfer and high-temperature deformation behavior of glass is an important issue. In this paper, a two-step pressing process is proposed according to the non-linear thermal expansion characteristics of glass. Heat transfer phenomenon was modeled by considering the temperature dependence of specific heat and thermal conductivity of glass. Viscosity of glass near the softening point was measured by uniaxially pressing cylindrical glass preforms between a pair of flat molds using an ultraprecision glass molding machine. Based on the numerical models and experimentally measured glass property, thermo-mechanical finite element method simulation of temperature rise during heating and material flow during pressing was carried out. The minimum heating time and pressing load changes were successfully predicted.

Modeling high-temperature glass molding process by coupling heat transfer and viscous deformation analysis

Investigation on the viscoelasticity of optical glass in ultraprecision lens molding process

Glass molding press (GMP) has been applied to produce the microgrooves on glass plates by using electroless-plated nickel phosphorus (Ni–P) molds. The GMP process for microgrooves was analyzed by finite element method (FEM) simulation. The effects of various pressing conditions, such as the molding temperature, the pressing velocity and the friction in glass deformation, were studied. Then, based on the simulation results, optimal pressing conditions were determined and used in the GMP experiments. By comparing the shape of the molded microgrooves with that of the corresponding microgrooves on the Ni–P mold, the shape transferability was evaluated and the reasons for form error were analyzed. The results show that the GMP process is an effective way to fabricate precision microgrooves on glass.

/pdf/investigation-on-shape-transferability-in-ultraprecision-1twg9w04mb.pdf

Investigation on shape transferability in ultraprecision glass molding press for microgrooves

Optical microstructures are increasingly applied in several fields, such as optical systems, precision measurement, and microfluid chips. Microstructures include microgrooves, microprisms, and microlenses. This paper presents an overview of optical microstructure fabrication through glass molding and highlights the applications of optical microstructures in mold fabrication and glass molding. The glass-mold interface friction and adhesion are also discussed. Moreover, the latest advancements in glass molding technologies are detailed, including new mold materials and their fabrication methods, viscoelastic constitutive modeling of glass, and microstructure molding process, as well as ultrasonic vibrationassisted molding technology.

/pdf/recent-advancements-in-optical-microstructure-fabrication-3a8nmnpvjt.pdf

Tianfeng Zhou

Papers

Precision machining of microstructures on electroless-plated NiP surface for molding glass components

Modeling high-temperature glass molding process by coupling heat transfer and viscous deformation analysis

Investigation on the viscoelasticity of optical glass in ultraprecision lens molding process

Investigation on shape transferability in ultraprecision glass molding press for microgrooves

Recent advancements in optical microstructure fabrication through glass molding process