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<p>With excellent mechanical and electrochemical properties, nickel-phosphorus (Ni-P) coating is widely used in optical engineering and precision physics experiments. Improving the machining quality and machining efficiency of Ni-P coated curved surface precision machining is vital to the performance of high-end equipment. However, the Ni-P alloy possesses high hardness and brittle characteristics, which are the typical features of a difficult-to-machine material. Meanwhile, the fluctuation of material removal rate (MRR) in the coated curved surface finishing machining causes the variation of the cutting force, which also adversely affects the improvement of the surface quality of Ni-P coating. In this study, finite element simulation and precision cutting experiments are first conducted to analyze the critical cutting parameters for the brittle-ductile transition in cutting Ni-P coating. With the ductile removal of the Ni-P coating, to effectively optimize the material removal process, an analytic model for the determination of MRR in the coated curved surface precision cutting is purposely built. Then, the optimization of the machining parameters based on the genetic algorithm (GA) modified particle swarm optimization (PSO) algorithm (GA-mPSO) is proposed to improve the machining efficiency and the surface quality of Ni-P curved coating finishing machining. The experimental results show that the machining efficiency is increased by 51.9%, and the surface roughness is reduced by 27.73% compared to the curved surface Ni-P coating machined by the constant spindle speed method. This study provides important guidance for the precision machining of Ni-P coated curved surfaces.</p>

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Investigation on Ductile-brittle Transition of Ni-P and Ductile-Regime Removal of Coated Curved Surface with Intelligent Optimization of MRR

  • 期刊论文

  • 发表日期：

    2026年3月18日

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  • Feng-ze Qin,
  • Zhixiang Chen,
  • Guibao Tao,
  • Chunjin Wang,
  • Chi Fai Cheung,
  • Huajun Cao

摘要

With excellent mechanical and electrochemical properties, nickel-phosphorus (Ni-P) coating is widely used in optical engineering and precision physics experiments. Improving the machining quality and machining efficiency of Ni-P coated curved surface precision machining is vital to the performance of high-end equipment. However, the Ni-P alloy possesses high hardness and brittle characteristics, which are the typical features of a difficult-to-machine material. Meanwhile, the fluctuation of material removal rate (MRR) in the coated curved surface finishing machining causes the variation of the cutting force, which also adversely affects the improvement of the surface quality of Ni-P coating. In this study, finite element simulation and precision cutting experiments are first conducted to analyze the critical cutting parameters for the brittle-ductile transition in cutting Ni-P coating. With the ductile removal of the Ni-P coating, to effectively optimize the material removal process, an analytic model for the determination of MRR in the coated curved surface precision cutting is purposely built. Then, the optimization of the machining parameters based on the genetic algorithm (GA) modified particle swarm optimization (PSO) algorithm (GA-mPSO) is proposed to improve the machining efficiency and the surface quality of Ni-P curved coating finishing machining. The experimental results show that the machining efficiency is increased by 51.9%, and the surface roughness is reduced by 27.73% compared to the curved surface Ni-P coating machined by the constant spindle speed method. This study provides important guidance for the precision machining of Ni-P coated curved surfaces.