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NEWTRENDSANDPROBLEMSINMATERIALPROCESSINGMACHINEDESIGNTHEORYWANGAILUN,DUANJIAN,HUANGMINGHUI,ZHONGJUECOLLEGEOFMECHANICALANDTHEREAFTERABRIEFDISCUSSIONISGIVENKEYWORDSINTERFACEEXTRAORDINARYPHYSICALFIELDPROCESSIONMACHINEFUNCTIONMATERIAL1THETIMEBACKGROUNDOFMATERIALPROCESSINGMACHINEINTHELONGSPANOFHISTORYOFHUMANPROGRESS,MANYTOOLS,MACHINESANDMETHODSWERECREATEDANDAVARIETYOFMATERIALSWITHDIFFERENTPROPERTIESWEREPROCESSEDMATERIALSANDITSPROCESSINGHAVEBECOMEONEOFPILLARANDDRIVINGFORCEOFMANKINDPROGRESSINPACEWITHMULTIPOLARCOMPETITIONINCURRENTWORLDANDPEOPLESSTRIVINGPERSEVERINGLYFORHAPPIERLIFE,MATERIALFUNCTIONGOESBEYONDUNCEASINGLYMENSKNOWLEDGEANDIMAGINATION,FOREXAMPLE,CRYPTICFUNCTIONMATERIAL,SEMICONDUCTORMATERIAL,ENERGYMATERIAL,VIBRATIONABSORPTIVEMATERIAL,SUPERSTRENGTHALUMINUMALLOYACCOUNTINGFOR70PERCENTOFAPPLICATIONOFAERONAUTICSANDSPACE,METALFOILOF45M,DEEPDRAWINGPLATEWITHANISOTROPYBELOW1PERCENT,ELECTRONICALUMINUMFOILWITHMICROORIENTATIONUPTO95PERCENT,HEATRESISTINGALUMINUMALLOYWITHSUPERSTRONGSPECIFICSTRENGTHUSEDINAERONAUTICS,SPACEANDDEEPSEA,ETCTHUSSEVERALIMPORTANTDEVELOPMENTTRENDSWITHDISTINCTTIMEFEATURESINMATERIALPROCESSINGDOMAINARESHAPEDUPASFOLLOWS1CREATINGMATERIALPROCESSINGMACHINEWITHEXTRAORDINARYPHYSICALFIELDFORPROCESSINGMATERIALWITHSPECIALTEXTURESTRUCTURESANDFUNCTIONSFOREXAMPLE,APPLICATIONSOFTHERMALENERGYANDMECHANICALENERGYAREBREAKINGTHROUGHUNCEASINGLYTECHNOLOGYLIMIT,ANDSOMENONTRADITIONENERGY,SUCHASMICROWAVE,CHEMICALENERGY,BIOENERGY,ETC,AREINTRODUCEDINTOMATERIALPROCESSINGPROCEDUREONEAFTERANOTHER,SOTHATSOMEMATERIALPROCESSINGMACHINESWITHEXTRAORDINARYENERGYCIRCUMSTANCEAREPRODUCED2BREAKINGTHROUGHTRADITIONALPHYSICALLIMITSANDINTEGRATINGMELTING,SOLIDIFYING,PLASTICDEFORMATIONANDHEATTREATMENTTOOBTAINSPECIALFUNCTIONOFMATERIALANDCUTDOWNEXPENSES3FOREXAMPLE,NEARNETSHAPINGMATERIALPROCESSINGTECHNOLOGY,SUCHASFASTROLLING,SPRAYINGDEPOSITION,OVERPLASTICMOLDING,INJECTIONMOLDING,HIGHENERGYBEAM,ETC,ISAPPLIED3MATERIALPROCESSINGPROCESSISFORGEDAHEADINTHEDIRECTIONOFHIGHSPEED,HEAVYDUTYANDHIGHACCURACYONLINECONTROL,FORINSTANCE,THEROLLINGSPEEDGOESUPTO130MS1,THEDEFORMATIONPRESSURERISESUPTO300MPA,ACCURACYOFDIMENSIONUPTO01M,ACCURACYOFSHAPEUPTO01I,STRENGTHACCURACYCOMESUPTO01MPAFORTHESEREASONS,ITISNECESSARYFORMATERIALPROCESSINGMACHINEDESIGNTHEORYTOINTEGRATEANDCOALESCEINGENIOUSLYCORRELATIVEFRONTIERSCIENCEANDTECHNOLOGYTOCREATEANDPRODUCESOMENEWCONCEPTMATERIALPROCESSINGMACHINEWITHFOLLOWINGFUNCTIONS2DUEFUNCTIONSOFNEWCONCEPTMATERIALPROCESSINGMACHINE1TOHAVETHEABILITYTOPRODUCEANDBEAREXTRAORDINARYPHYSICALFIELDANDTRANSMITEXTRAORDINARYENERGYFLOWWITHTHEAIMOFPROVIDINGEXTRAORDINARYPHYSICALCIRCUMSTANCESNECESSARYFORNEWCONCEPTMATERIALPROCESSINGFOREXAMPLE,HIGHGRADIENTTEMPERATUREFIELDWITHTHESPEEDOFCOOLDOWNOFWORKINTERFACEWHICHEXCEEDS104106KS1,LINEWAVEANDPULSECOMPLEXEXERTEDINSOLIDIFYINGDEFORMINGAREA,SUPERSTRENGTHCONTACTSTRESSFIELDOFMATERIALFORMINGINTERFACE,TURBULENTFLOWFIELDOFMOLTENMETALWITHVERYBIGFLAKINESSRATIO,LOWFREQUENCYMAGNETICFIELDWITHRANDOMFREQUENCY,MICROWAVEFIELDFORPOWDERMETALHEATING,ULTRASONICFIELDFORLARGEVOLUMESOLIDIFYING,ETC4,AREAPPLIED2TOHAVETHEABILITYTOWORKINCRITICALSTATESOTHATHIGHSTABILITYANDIDEALPERFORMANCEOFPROCESSINGMACHINEISENSUREDUNDERTHECIRCUMSTANCEOFREINFORCEDTECHNOLOGICALCONDITIONANDMULTIFIELDCOUPLINGOPERATIONFOREXAMPLE,CHATTERSUPPRESSINGCAPABILITYOFFASTULTRATHINROLLINGUNDERTHECONDITIONOFBOUNDARYLUBRICATINGSTATE5,THECAPABILITYOFSELFEXCITEDVIBRATIONSUPPRESSINGUNDERTHECONDITIONOFSPECIALFRICTIONSTATE,SYNERGISMSTABILITYANDDISTURBANCESTABILITYOFFLEXIBLECONNECTINGPARALLELSHAFTWITHMULTIDRIVINGSYSTEM,ETC4,AREENSURED3TOHAVETHEABILITYTOACCURATELYCONTROLTHEMATERIALPROCESSINGINORDERTOOBTAINLOWLOSS,HIGHEFFICIENCYANDHIGHQUALITYOFMATERIALPROCESSINGFOREXAMPLE,SUPERHIGHACCURACYONLINEMONITOROFPRODUCTSFORM,ONLINEMONITORANDONLINEADJUSTMENTOFPRODUCTSTEXTUREANDPROPERTIES,PRECISIONCOORDINATIONCONTROLOFMULTIPROCEDURE,ONLINEMONITOROFMICROORIENTATIONOFMETALPLASTICDEFORMATION,ETC4,AREENSUREDSOMEPRODUCTSACCURACYINDEXMAYBEENUMERATEDASFOLLOWSDIMENSIONALACCURACYCOMINGTO01M,MICROSTRUCTUREUNIFORMITYTOCRYSTALLATTICE,STRENGTHERRORTO01MPA,ETC4INSHORT,ONLYBYNEWCONCEPTMATERIALPROCESSINGMACHINEWITHEXTRAORDINARYFUNCTIONBEINGDESIGNEDANDMADE,CANSPECIALFUNCTIONMATERIALBEPROCESSED3SCIENCEPROBLEMSANDSTUDYCONTENTSOFMETALMATERIALPROCESSINGMACHINEUNDERTHECIRCUMSTANCEOFEXTRAORDINARYPHYSICALFIELDINVIEWOFTHESEFACTSANDBACKGROUNDMENTIONEDABOVE,SEVERALNEWRESEARCHTOPICSCANBEADVANCEDASFOLLOWS31COUPLINGHEATTRANSFERMECHANISMOFMULTIPHASEINTERFACETEMPERATURESTRESSFIELDABRANDNEWMICROSTRUCTURECANBEOBTAINEDTHROUGHCONTINUOUSLYLARGEDEFORMATIONANDFASTSOLIDIFYINGWHENMELTINGMETALISINCRITICALSTATEOFLIQUIDSOLIDATTHISVERYMOMENT,HIGHDENSITYHEATFLOWANDDYNAMICHEATRESISTANCEAREPRESENTINMATERIALPROCESSINGCIRCUMSTANCEABASICTHEORYPROBLEMOFDESIGNINGTHISKINDOFMACHINEISTOSTUDYMECHANISMOFHEATTRANSMITTANCEANDENERGYCONVERSION,ANDTOESTABLISHMATHEMATICALMODEL32FRICTIONCONSTRAINTMECHANISMOFPLASTICFLOWINTERFACEOFMATERIALPROCESSINGMACHINETHECOUPLINGBETWEENOPERATIONMECHANISMANDWORKPIECEISVERYCOMPLICATEDBECAUSEPLASTICFLOWISPRESENTINPROCESSINGINTERFACETHEINTERFACESTATE,DETERMINEDBYVELOCITY,LOADTHERMODYNAMICPROCESS,ELASTICITYOFOPERATIONMECHANISM,PLASTICITYOFWORKPIECE,DYNAMICBEHAVIOUROFINTERFACESTICKINGSLIDINGANDPARTIALHYDRODYNAMICLUBRICATION,ETC,AFFECTANDFORMFRICTIONCONSTRAINTSMECHANISMPECULIARTOMATERIALPROCESSINGMACHINE,BECAUSETHESECONSTRAINTSPRESENTSTRONGNONLINEARITYANDUNDERCERTAINCIRCUMSTANCES,THECONSTRAINTSMAYBEDESTROYEDORMISMATCHEDINSTANTANEOUSLYANDTHUSDYNAMICINSTABILITYISRESULTEDINTHUSFOLLOWINGPROBLEMSCANBEPUTFORWARDMECHANISMOF“SPECTRECHATTER”AROSEFROMSTICKINGSLIDINGFRICTIONANDPARTIALHYDRODYNAMICLUBRICATIONINROLLINGINTERFACE,INSTABILITYCONDITIONANDMECHANISMOFCONSTRAINTBETWEENSMOOTHSURFACEANDROTATINGBODYUNDERTHECIRCUMSTANCEOFHIGHSPEED,HEAVYDUTYANDBOUNDARYLUBRICATION,LUBRICATIONFILMABSORPTIONMECHANISMANDPHYSICALCHEMISTRYBEHAVIOUROFINTERFACEOFUNCEASINGLYREGENERATIVESURFACE,THERELATIONSHIPBETWEENRHEOLOGICALCHARACTERISTICANDMACHINEOPERATIONPARAMETERS33MULTIBODYNONLINEARCONTACTMECHANISMUNDERTHECONDITIONOFEXTRAHIGHPRESSUREFIELDTOBUILDTHESUPERSTRENGTHPRESSUREFIELDONLARGEAREAISONEOFBASICFUNCTIONOFMATERIALPROCESSINGMACHINE,ANDITISALSONECESSARYTOFORMBYONCELARGESIZESTRUCTUREELEMENTSUCHASSPACECRAFT,INTERCONTINENTALVEHICLES,CARANDLARGESCALEAEROPLANEETCTHEABILITYTOBUILDSUPERSTRONGPRESSUREFIELDISONEOFIMPORTANTFEATUREANDTHEBASEOFINDEPENDENTNATIONALDEFENSEUNDERTHECIRCUMSTANCEOFSUPERSTRENGTHPRESSUREFIELD,MULTIBODYSTRONGNONHERTZCONTACTANDNONLINEARFRICTIONWILLBEPRODUCED,THUSLOCALPERMANENTDEFORMATIONANDDEGRADINGOFELEMENTACCURACYMAYBELEDNEWTHEORYFOUNDATIONOFDESIGNOFMACHINEWITHSUPERSTRENGTHPRESSUREFIELDWILLBEFURNISHEDTHROUGHSTUDYOFMULTIBODYSTRONGNONHERTZCONTACTMECHANISM,MULTIBODYNONLINEARFRICTIONMECHANISMSUCHASPROVIDINGFORCEDISPLACEMENTMIXEDSOLVINGPROCESSOFTHREEDIMENSIONMULTIBODY34LOADDISTRIBUTIONLAWINMULTISLIDINGPAIRWITHSTRUCTUREBIASLOADWITHREGARDTOSTATICALLYINDETERMINATESTRUCTURE,LOADDISTRIBUTIONOFCONSTRAINTPOINTISDETERMINEDBYDEFORMATIONCOMPATIBILITYCONDITIONHOWEVER,CONCERNINGSOMEPLANELARGESIZESTATICALLYINDETERMINATESTRUCTUREWITHSLIDINGDEGREEOFFREEDOMINTHIRDDIMENSION,LOADDISTRIBUTIONCANNOTBEDETERMINEDBYDEFORMATIONCOMPATIBILITYCONDITIONTHUSNEWTHEORYBASISWILLBEPROVIDEDBYANALYZINGOFCONTACTBEHAVIOURANDMECHANISMOFSLIDINGPAIRSUCHASCREEP,FORCEOFFRICTION,INTEGRALDEFORMATIONCOMPATIBILITYCONDITION,ETC35COUPLINGMECHANISMANDSTABILITYOFMULTIPHYSICALFIELDSINMATERIALPROCESSINGSYSTEMSINTHEWAKEOFSYSTEMFUNCTIONBECOMINGMOREANDMOREDIVERSIFIED,CONVENTIONALTECHNOLOGYLIMITSINMATERIALPROCESSINGMACHINEISBEINGBROKETHROUGHUNCEASINGLY,SYSTEMSTRUCTUREALSOBECOMESINCREASINGLYCOMPLICATED,ANDSYSTEMPERFORMANCEBECOMESINCREASINGLYMULTICAUSALFOREXAMPLE,ANYINSTANTANEOUSSTATEOFROLLERINFASTROLLINGMILLSISAFFECTEDBYELASTICDEFORMATION,PLASTICFLOW,HEATTRANSFERPROCESS,HYDRODYNAMICLUBRICATIONPROCESS,INTERFACEPHYSICALCHEMISTRYMOLECULARSTATEANDSOONINADDITION,ELECTROMECHANICALCOUPLINGINPROCESSINGSYSTEMHAVEALREADYGONEBEYONDCONVENTIONALCONCEPT,FORINSTANCE,SOMESINGULARPOINTPHENOMENONSUCHASMICROVARIABLECANBETRANSFORMEDINTOMACROVARIABLE,AREPRESENT,THUSROLLEROPERATIONINSTABILITYMAYBELEDBYPERTURBATION8THEREFORE,THISSUBJECTWILLSTUDYTHEINTERACTIONMECHANISMOFMULTIPHYSICALFIELDANDTHEINFLUENCEONPROCESSINGSYSTEMSTABILITYANDPROCESSINGMATERIALQUALITYSTARTEDWITHANALYSISOFMICROSTATEOFEXECUTIVEBODY36MULTITECHNOLOGYINTEGRATIONANDCOALESCENCEOFACCURATECONTROLTHEMATERIALPROCESSINGMACHINE,WHICHOPERATEUNDERTHECIRCUMSTANCEOFEXTRAORDINARYPHYSICALFIELD,ISACOMPLICATEDLARGESCALESYSTEM,ANDSOMEPARAMETERSOFTHESYSTEMVARYONFEASIBLEFIELDBOUNDARYTHEREBY,TOKEEPUNDERACCURATECONTROLANDADJUSTMENTOFMULTIFIELDCIRCUMSTANCE,MULTIDIMENSIONCOORDINATION,MULTIENERGYCONVERSION,MULTILEVELINFORMATIONTRANSFER,INTERFACEMULTIPROCESSCOUPLING,ETCISOFMUCHSIGNIFICANCESINCEAVARIETYOFMULTIINTERACTIONEXISTSINCONTROLMODEL,ITISNECESSARYTOESTABLISHINTEGRATIONFRAMEWORKOFCOORDINATIONWORKACCORDINGTODECOUPLINGOFCONTROLMODEL,SOASTOACCURATECONTROLBASEDONTHEMULTITECHNOLOGYINTEGRATIONANDCOALESCENCEISREALIZED37QUASIREALITYDESIGNANDCONCURRENTDESIGNBASEDONKNOWLEDGEINNOVATIONSYSTEMSDIGITALIZATIONANDVISUALIZATIONOFMATERIALPROCESSINGTECHNOLOGYWILLPROMOTEIMMEDIATELYTHEQUALITYOFDESIGN,OPERATIONANDCONTROLTHEREFOREOPTIMIZATIONOFMATERIALPROCESSINGTECHNOLOGYANDMATERIALPROCESSINGMACHINEBYMEANSOFREALIZATIONOFVIRTUALSIMULATIONOFPROCESSINGPROCEDURETHROUGHQUASIREALITYDESIGNANDCONCURRENTDESIGNISONEOFOURPRESSINGSTUDYSUBJECTS38MECHANICALBEHAVIOROFSPECIALFUNCTIONMATERIALSINTHEEXTRAORDINARYPHYSICALFIELDMANYKEYELEMENTSANDPARTSINMATERIALPROCESSINGMACHINEAREOFTENUNDERTHECIRCUMSTANCEOFSUPERSTRONGFORCEFIELD,TEMPERATUREFIELD,ELECTRONICMAGNETICFIELDANDFLOWFIELD,ANDMUSTHAVETHEFUNCTIONSOFCONSTRUCTINGSPECIALPHYSICALINTERFACEHOWEVER,ITISDIFFICULTFORCOM