An innovative multi-energy field-assisted ultra-precision machining technology: in-situ laser-magnetic dual-field assisted diamond cutting

Abstract Field-assisted diamond cutting technology is a significant machining method that utilizes external energy fields to enhance the manufacturing performance. However, aimed the emergence of advanced high-performance materials, traditional single-field-assisted machining struggles to meet stringent precision requirements. Therefore, this study introduces an innovative and unique multi-energy field-assisted ultra-precision machining technology, in-situ laser-magnetic dual-field assisted diamond cutting (LMDFDC), to transcend the limitations of conventional single-field-assisted cutting methods and advance the machinability of challenging materials, notably the multi-principal-element high-entropy alloy (HEA). To elucidate the fundamental science questions of “what occurs, what changes, and what improves” in this work, the phenomenological behaviors of the dual-field coupling interaction are systematically investigated through advanced characterization techniques, spanning macroscopic surface integrity to microscopic atomic arrangement. This comprehensive study encompasses integrated analyses of four machining techniques for HEA workpiece, namely dual-energy field, two single-energy fields, and no-energy field. The research results indicate that the dual-field coupling effect demonstrates a leap in manufacturing performance through thermo-magneto-mechanical multi-physical synergistic interactions, primarily manifested in improved surface quality, reduced subsurface damage, suppressed diamond tool wear, and enhanced material removal stability. The significance of in-situ LMDFDC technology resides in propelling frontier academic developments in multi-physics coupled manufacturing theories while uncovering innovative machining approaches for next-generation high-performance materials.