A team at The Hong Kong Polytechnic University has created a machining method that takes a clear step beyond all existing field-assisted cutting techniques. Instead of using only one external energy field, such as heat or magnetism, the new approach applies a laser field and a magnetic field at the same time during diamond cutting. This dual-field method offers a way to machine advanced materials that are extremely difficult to process with conventional techniques.
Field-assisted machining has been used for years to support precision manufacturing. But these traditional methods rely on just one type of assistance, which increasingly falls short as industries turn to new high-strength materials. High-entropy alloys (HEAs), for example, are a promising class of metals with potential applications in aerospace, energy, and other demanding fields. Their exceptional properties, however, also make them very challenging to machine with accuracy.
To overcome these limits, Prof. Suet To and her co-workers developed an in-situ laser–magnetic dual-field assisted diamond cutting technique. Their study, published in the International Journal of Extreme Manufacturing , is the first to thoroughly examine how laser and magnetic fields work together during ultra-precision machining, and how this combined action differs from using either field alone.
The team compared four machining conditions: dual-field cutting, laser-only, magnetic-only, and cutting without any external field. They analyzed the results using a suite of advanced tools that allowed them to observe changes at multiple levels, from the appearance of the surface to subsurface features and even atomic-scale structures. This approach helped them answer three key questions: What happens when both fields are applied together? What changes inside the material? And what improvements follow from those changes?
Their findings show that the dual-field approach produces effects that neither the laser nor the magnetic field can achieve on their own. The laser softens the material locally, while the magnetic field influences how the material flows and how it interacts with the diamond tool.
Together, they create a combined thermo-magneto-mechanical environment that leads to several benefits: smoother machined surfaces, less damage beneath the surface, more consistent removal of material, and noticeably reduced tool wear.
"This approach allows us to go beyond the limits of existing machining methods," said Prof. To. "By applying two energy fields at the same time, we can create conditions that improve machinability in a way no single field can provide."
High-entropy alloys are among the materials that stand to benefit most. Their superior strength and stability make them attractive for advanced engineering applications, but they are difficult to cut precisely. The dual-field method offers a promising way to fully unlock their potential.
First author Yintian Xing emphasized that their study provides not only a new machining technology but also a deeper scientific understanding. "By studying everything from overall surface characteristics to atomic structure, we can clearly see what occurs, what changes, and what improves when laser and magnetic fields act together," he explained. "This knowledge gap is important for designing future multi-field machining methods."
The researchers plan to expand their work by studying more types of energy-field combinations and testing other advanced materials. Their findings contribute to the growing field of multi-physics machining and point toward more versatile and reliable approaches for fabricating next-generation high-performance materials.
International Journal of Extreme Manufacturing (IJEM, IF: 21.3) is dedicated to publishing the best advanced manufacturing research with extreme dimensions to address both the fundamental scientific challenges and significant engineering needs.
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