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In this study, we propose a longitudinal-torsion ultrasonic-assisted milling (LTUM) machining method for difficult-to-cut materials—such as titanium alloy—in order to realize anti-fatigue manufacturing. In addition, a theoretical prediction model of cutting force is established. To achieve this, we used the cutting edge trajectory of LTUM to reveal the difference in trajectory between LTUM and traditional milling (TM). Then, an undeformed chip thickness (UCT) model of LTUM was constructed. From this, the cutting force model was able to be established. A series of experiments were subsequently carried out to verify this LTUM cutting force model. Based on the established model, the influence of several parameters on cutting force was analyzed. The results showed that the established theoretical model of cutting force was in agreement with the experimental results, and that, compared to TM, the cutting force was lower in LTUM. Specifically, the cutting force in the feed direction, Fx, decreased by 24.8%, while the cutting force in the width of cut direction Fy, decreased by 29.9%.

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Electrochemical carbon dioxide (CO2) conversion to hydrocarbon fuels, such as methane (CH4), offers a promising solution for the long-term and large-scale storage of renewable electricity. To enable this technology, CO2-to-CH4 conversion must achieve high selectivity and energy efficiency at high currents. Here, we report an electrochemical conversion system that features proton-bicarbonate-CO2 mass transport management coupled with an in-situ copper (Cu) activation strategy to achieve high CH4 selectivity at high currents. We find that open matrix Cu electrodes sustain sufficient local CO2 concentration by combining both dissolved CO2 and in-situ generated CO2 from the bicarbonate. In-situ Cu activation through alternating current operation renders and maintains the catalyst highly selective towards CH4. The combination of these strategies leads to CH4 Faradaic efficiencies of over 70% in a wide current density range (100 – 750 mA cm-2) that is stable for at least 12 h at a current density of 500 mA cm-2. The system also delivers a CH4 concentration of 23.5% in the gas product stream.