This study investigates the effect of process parameters on neurosurgical bone grinding performance using a miniature surgical diamond wheel. Bone grinding is an important procedure in the expanded endonasal approach for removing the cranial bone and access to the skull base tumor via nasal corridor. Heat and force are generated during the grinding process, which may cause thermal and mechanical damage to the adjacent tissues. This study investigates the effect of grinding process parameters (including the depth of cut, feed rate, and spindle speed) on the bone grinding performance using temperature and force measurement sensors in order to optimize the grinding process. An orthogonal experimental design with a standard orthogonal array, L₉ (3³), is selected with each parameter in three levels. The experimental results have been statistically analyzed using the range and variance analysis methods in order to determine the importance order of the process parameters. The results indicate that the effect of the cutting depth on the grinding temperature and normal force is the largest, while the effect of the spindle speed on the tangential force is the largest. A high spindle speed would make the temperature rise to a certain extent; however, it significantly reduces the grinding force. At a certain spindle speed, a lower depth of cut and feed rate help to reduce the grinding temperature and force.

To optimize the rigidity and dynamic mechanical properties of a sawing machine and improve its processing quality and stability, a design method for the sawing machine’s gearbox was proposed. First, a lightweight design of the gearbox was realized by topology optimization. Second, the sensitivity of different design variables of the new gearbox was determined via sensitivity analysis of the objective function. Finally, multi-objective optimization was used to obtain the optimal solution for the gearbox. Considering the complexity of the internal structure of the gearbox assembly and the accuracy of the numerical calculation process, a modeling method with mass points was proposed. A comparison between the numerical calculation results and the operation mode analysis revealed that the former was accurate and can be applied to the verification of the optimized gearbox. By optimizing the vibration signals before and after, and the analysis of the end face quality of the workpiece, the results revealed that the optimized gearbox has a significantly reduced amplitude under various operating conditions. In addition, the vibration stability was improved, and the end face quality of the workpiece was significantly enhanced compared to that before optimization. This study serves as a theoretical reference for multi-body dynamics modeling and optimization of machine tools, and also outlines technical solutions for high-speed stable cutting with sawing machines.

To address the issue of uneven pressure distribution in the abrasive flow field within the inner hole of components with a large depth/diameter ratio, an adaptive control strategy for regulating flow field pressure difference is proposed in this paper. The strategy was based on the effects of pressure fluctuations at the abrasive flow inlet and outlet on pressure distribution patterns and pressure changes within the inner hole flow field, as derived from numerical simulations. An adaptive control fixture was also designed, enabling dynamic adjustments to the fixture gap, which significantly reduced the pressure difference in the flow field. Experimental results demonstrated that the surface texture uniformity of the inner hole was greatly improved after adaptive control. The non-uniformity in surface roughness after control was 59.1% lower compared to pre-control conditions, indicating improved machining consistency. Furthermore, the maximum reduction in surface roughness increased from 1.146 μm to 1.844 μm, and processing efficiency was notably enhanced.

Gun barrels are subjected to time-varying high-intensity heat flux under multiple firing, which may damage the material and limit the overall performance of the gun. In order to monitor the thermal state of a gun barrel, an inverse method coupling the finite difference method with the sequential function specification method was developed to estimate the unknown time-varying heat flux imposed on the inner wall of a gun barrel. A two-layer hollow cylindrical tube was assumed with the convection heat transfer boundary condition on the outer wall of the tube. A direct heat transfer model was developed, and was used to estimate the temporal distribution of boundary heat flux in approximately real time based on the measured transient temperature at some positions on the outer wall of the gun barrel. Numerical tests were performed to verify the effectiveness and reliability of this method by investigating the influence of temperature measurement noises and future time step selection. The results show that the proposed method has high precision and efficiency in extracting the time-varying heat flux under one-shot and three-shot firing conditions. When there is a measurement noise, this method has good anti-illness characteristics and can achieve better results by appropriately selecting the value of a future time step.