Intelligent and Sustainable Manufacturing

Guide for Authors Submit to ISM

Multi-energy Field High Performance Machining for Difficult-to-cut Aerospace Materials

Deadline for manuscript submissions: 30 September 2025.

Guest Editors (2)

Benkai Li
Prof. Dr. Benkai Li 
School of Mechanical and Automotive Engineering, Qingdao University of Technology, Qingdao 266520, China
Interests: High-performance Grinding of Difficult-to-cut Materials using Multi Field
Website: https://mae.qut.edu.cn/info/1038/6167.htm
Biao Zhao
Prof. Dr. Biao Zhao 
College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China
Interests: High-efficiency and Precision Cutting/Grinding Technology; High-performance Tools; Cutting/Grinding Mechanism and Process Optimization
Website: https://www.researchgate.net/profile/Biao_Zhao10

Special Issue Information

With the advancement of global carbon emission reduction strategies and the rapid development of the aerospace industry, high-strength, heat-resistant difficult-to-cut materials (such as nickel-based superalloys, titanium alloys, ceramic matrix composites, etc.) have become core materials for critical components like aero-engine parts and spacecraft structural components. However, these materials exhibit high hardness, high toughness, and low thermal conductivity, making them typical difficult-to-cut materials. Traditional machining technologies face challenges such as excessive cutting forces, high cutting temperatures, severe tool wear, and poor surface integrity, which severely constrain machining efficiency and component service performance.

In recent years, multi-energy field-assisted machining technologies (e.g., ultrasonic vibration, electrostatic atomization, magnetic field modulation) have demonstrated significant advantages in reducing cutting forces, improving heat dissipation conditions, and suppressing machining defects through energy coupling and dynamic regulation mechanisms. To further promote innovative applications of these technologies in aerospace manufacturing, this special issue focuses on interaction mechanisms between multi-energy fields and difficult-to-cut materials, process optimization, and sustainability enhancement, soliciting cutting-edge research and technological breakthroughs to advance aerospace manufacturing toward high performance, low energy consumption, and high precision.

This special issue covers (but is not limited to) the following research areas:

1. Coupling Mechanisms and Dynamic Regulation of Multi-energy Fields
  1. Synergistic interaction mechanisms of ultrasonic/electrostatic/magnetic fields with cutting/grinding processes
  2. Parameter optimization and energy transfer efficiency enhancement in multi-energy field systems
  3. Field-material interaction behavior under extreme conditions (high temperature, high strain rate)
2. High-Efficiency Material Removal and Surface Integrity Control for Difficult-to-Cut Materials
  1. Low-damage cutting and grinding techniques for nickel-based superalloys/titanium alloys
  2. Delamination suppression and edge quality optimization for ceramic matrix composites
  3. Thermo-mechanical-chemical coupling simulations in hybrid energy field-assisted machining
3. Integration of Green and Sustainable Machining Technologies
  1. Hybrid applications of multi-energy fields with minimum quantity lubrication (MQL), cryogenic air cooling, etc.
  2. Permeation and film-forming mechanisms of bio-lubricants for friction reduction and efficiency improvement
  3. Carbon emission modeling and energy efficiency evaluation in machining processes
4. Intelligent Equipment and Advanced Tool Development
  1. Design and control technologies for dedicated multi-energy field machining equipment
  2. Fabrication and anti-adhesion performance of micro-textured cutting tools/grinding wheels
  3. In-situ monitoring and adaptive machining systems

Published Papers (3 Papers)

Open Access

Review

09 July 2025

Muti-Energy Field-Assisted Grinding of Hard and Brittle Materials: Tools, Equipment and Mechanisms

Hard, brittle and difficult-to-machine materials are prone to surface cracks, subsurface damage and other defects in the traditional grinding process, accompanied by low processing efficiency and severe tool wear. As a new type of processing technology, energy field-assisted grinding provides a new approach for the efficient and high-quality processing of hard and brittle materials. This paper reviews the latest research progress of muti-energy field-assisted grinding from aspects such as the types and selection of grinding tools, processing equipment and physical-chemical coupled mechanisms. Firstly, micro-grinding tools are classified based on different surface structures and coating materials, with the aim to enhance processing efficiency, improve the surface quality and geometric accuracy of workpieces, and reduce tool wear. Secondly, the processing mechanisms, parameter selection and current difficulties faced by four energy field-assisted grinding methods, including laser-assisted grinding, electrochemical-assisted grinding, magnetic-assisted grinding and ultrasonic field-assisted grinding, are discussed under both chemical and physical effects. Thirdly, different equipment and auxiliary devices developed for energy field-assisted grinding have been introduced, providing reliable platforms for the distribution design and efficient regulation of the energy field. Finally, the cutting-edge progress, main challenges and development trends of energy field-assisted grinding are prospected, illustrating the great potential of this technology in fields such as aerospace, electronics, and optical components.

Wentao Wang
Zhiyuan Zhou
Qing  Wang
Baixuan Gao
Cong Mao*
Intell. Sustain. Manuf.
2025,
2
(2), 10022; 
DOI: 10.70322/ism.2025.10022
Open Access

Review

29 September 2025

Robot Grinding: From Frontier Hotspots to Key Technologies and Applications

Robot grinding technology has shown broad application prospects in the field of machining complex curved parts due to its high flexibility, strong adaptability, and high automation. However, industrial robots are generally only suitable for rough machining, and for semi-finishing and finishing, improving the machining accuracy of robots and the surface quality of parts is a key issue. This paper summarizes the current research status of robot grinding and provides a reference for realizing robot precision grinding. At present, the research on robot grinding technology mainly focuses on robot pose control, force/position hybrid control strategy, intelligent machining path planning, vibration suppression technology, compliance control, and so on, aiming at solving the key bottleneck problems such as low machining accuracy, large grinding force fluctuation and poor surface quality consistency caused by insufficient robot stiffness. Firstly, the development history of the robot grinding system and the research status of process technology are summarized systematically. Secondly, the analysis focuses on grinding path planning, programming technology, and robot compliance force control technology. Finally, the current status of optimization research in robot grinding technology is summarized. The overarching purpose of this paper is to provide a systematic analysis and a comprehensive reference framework, aiming to address the core challenges hindering the achievement of high-precision, consistent surface quality in robotic grinding manufacturing. Based on the summarized state-of-the-art, robot grinding technology development trend is also predicted.

Zeming Li
Shuoshuo Qu*
Yang Sun
Yadong  Gong
Dongkai  Chu
Peng   Yao
Zhe  Li
Xinbo Xu
Intell. Sustain. Manuf.
2025,
2
(2), 10027; 
DOI: 10.70322/ism.2025.10027
Open Access

Review

14 November 2025

Advancements in Hybrid Abrasive Flow Finishing: Fundamentals, Technological Developments, and Industrial Applications in Precision Manufacturing

Hybrid-Based Abrasive Flow Finishing (HAFF) represents a significant evolution in precision manufacturing, particularly in addressing the inherent limitations of traditional finishing techniques when dealing with complex geometries and challenging materials. HAFF achieves remarkable precision in managing particle motion by blending state-of-the-art energy inputs and mechanical reinforcements, including sonic vibrations, electromagnetic influences, and beam-guided supports, which accelerate the pace of material extraction and elevate the overall finish of surfaces. This paper comprehensively reviews various HAFF approaches, including energy-assisted methods (e.g., electrochemical, ultrasonic, and laser), force-assisted techniques (e.g., magnetic, hydrodynamic, and vibration), and hybrid energy-force integrated systems. Recent advancements, such as cryogenic-assisted, rotational-assisted, and magnetorheological-assisted AFF, are also discussed in this review. Recent studies from 2023 to 2025 highlight improvements in material removal rates of up to 80% and reductions in surface roughness of over 90% across various HAFF variants, underscoring the timeliness of these developments. Incorporating diverse power sources and mechanical aids into HAFF allows for exact oversight of particle interactions, speeding up the removal of excess material, refining the exterior finish, and broadening its utility across detailed designs and tough-to-process substances. Despite significant progress, challenges persist in scaling HAFF processes for industrial applications, improving cost efficiency, and implementing effective real-time monitoring systems. The future trajectory of HAFF research will focus on the development of innovative abrasive media, advanced automation technologies, artificial Intelligence techniques, and sustainable manufacturing practices. This study examines all existing HAFF technology solutions and evaluates product applications for aerospace, automotive, medical equipment, and micro-manufactured devices. The discussion highlights the industries that require more advanced technological investigations.

Abdul Wahab Hashmi
Yebing Tian*
Hongjie  Sun
Arsalan  Ahmad
Chunjin  Wang
Dazhong  Wang
Mamilla Ravi  Sankar
Intell. Sustain. Manuf.
2025,
2
(2), 10031; 
DOI: 10.70322/ism.2025.10031
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