JZUS - Journal of Zhejiang University SCIENCE

Journal of Zhejiang University SCIENCE A

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Synergistic enhancement of machinability and surface integrity in bulk metallic glasses via cold plasma pretreatment and ultrasonic vibration-assisted micro-milling

Author(s): Qilin LI^1, ², Emek Babuskin KOCYIGIT^1, ², Long YE³, Nan YU³, Pingfa FENG^1, ², Jianjian WANG^1, ²
Affiliation(s): ¹State Key Laboratory of Tribology in Advanced Equipment, Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China ²Beijing Key Laboratory of Precision/Ultra-precision Manufacturing Equipment and Control, Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China ³Institute of Materials and Processes, School of Engineering, University of Edinburgh, Edinburgh, EH9 3FB, UK
Corresponding email(s): Jianjian WANG, wangjjthu@tsinghua.edu.cn
Key Words: Bulk metallic glass; Micro-milling; Cold plasma; Ultrasonic vibration; Surface integrity

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Qilin LI^1,², Emek Babuskin KOCYIGIT^1,², Long YE³, Nan YU³, Pingfa FENG^1,², Jianjian WANG^1,². Synergistic enhancement of machinability and surface integrity in bulk metallic glasses via cold plasma pretreatment and ultrasonic vibration-assisted micro-milling[J]. Journal of Zhejiang University Science A,in press.Frontiers of Information Technology & Electronic Engineering,in press.https://doi.org/10.1631/jzus.A2500552

@article{title="Synergistic enhancement of machinability and surface integrity in bulk metallic glasses via cold plasma pretreatment and ultrasonic vibration-assisted micro-milling",
author="Qilin LI^1,², Emek Babuskin KOCYIGIT^1,², Long YE³, Nan YU³, Pingfa FENG^1,², Jianjian WANG^1,²",
journal="Journal of Zhejiang University Science A",
year="in press",
publisher="Zhejiang University Press & Springer",
doi="https://doi.org/10.1631/jzus.A2500552"
}

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%T Synergistic enhancement of machinability and surface integrity in bulk metallic glasses via cold plasma pretreatment and ultrasonic vibration-assisted micro-milling
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%A Emek Babuskin KOCYIGIT^1
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%A Nan YU³
%A Pingfa FENG^1
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%A Jianjian WANG^1
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%J Journal of Zhejiang University SCIENCE A
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doi="https://doi.org/10.1631/jzus.A2500552"

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Abstract
Chinese Summary
Academic Network
Reviewer Comment

Abstract: Bulk Metallic Glasses (BMGs) exhibit exceptional properties, but are difficult to machine due to their high hardness and brittleness. In this study we propose a novel hybrid machining strategy integrating Cold Plasma (CP) pretreatment with Ultrasonic Vibration-assisted Micro-milling (UVAM), termed CP-UVAM, to overcome these challenges. We reveal the fundamental mechanism by which CP independently optimizes machining: it transforms the BMG surface from hydrophobic to super-hydrophilic (contact angle <10˚) through oxidation and the introduction of polar groups, thereby enhancing lubricant penetration. Crucially, CP treatment increases the near-surface free volume, significantly improving plastic deformability, as evidenced by nanoindentation (15-20% reduction in first pop-in force) and nano-scratching tests. Four methods-Conventional Milling (CM), CP-assisted Milling (CPAM), UVAM, and CP-UVAM-were systematically compared. While CPAM alone delivered the best surface finish and least tool wear, UVAM achieved a 29.02% cutting force reduction at the cost of severe tool edge chipping. The synergistic CP-UVAM approach retained the force reduction advantage of UVAM (34.36% reduction vs CM) while dramatically mitigating UVAM-induced tool damage, reducing edge chipping by 43.97% and achieving superior surface consistency (an Sa value of 2.601 µm in the stable state). This study demonstrates that CP independently enhances BMG machinability and works synergistically with UVAM, enabling high-precision micro-milling of this challenging material through the combination of plasma-induced plasticity and wettability with ultrasonic vibration-assisted force reduction.

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