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milling Force Model for Aviation Aluminum Alloy: Academic Insight and Perspective Analysis

Chinese Journal of Mechanical Engineering 2021年第1期34卷 54-88页

作者： Zhenjing Duan Changhe Li Wenfeng Ding Yanbin Zhang Min Yang Teng Gao Huajun Cao Xuefeng Xu Dazhong Wang Cong Mao Hao Nan Li Gupta Munish Kumar Zafar Said Sujan Debnath Muhammad Jamil Hafiz Muhammad Ali School of Mechanical and Automotive Engineering Qingdao University of TechnologyQingdao 266520China College of Mechanical and Electrical Engineering Nanjing University of Aeronautics and AstronauticsNanjing 210016China State Key Laboratory Mechanical Transmiss Chongqing UniversityChongqing 400044China Key Laboratory of Special Purpose Equipment and Advanced Processing Technology Ministry of Educati on&Zhejiang ProvinceZhejiang University of TechnologyHangzhou 310032China School of Mechanical and Automotive Engineering Shanghai University of Engineering ScienceShanghai 201620China College of Automotive and Mechanical Engineering Changsha University of Science and TechnologyChangsha 410114China School of Aerospace University of Nottingham Ningbo ChinaNingbo 315100China Key Lab High Efficiency and Clean Mech Manufacture Shandong UniversityJinan 250100China College of Engineering University of Sharjah27272 SharjahUnited Arab Emirates Mechanical Engineering Department Curtin University98009 MiriMalaysia Mecha nical Engineering Department King Fahd University of Petroleum and MineralsDhahran 31261Saudi Arabia

Aluminum alloy is the main structural material of aircraft,launch vehicle,spaceship,and space station and is processed by ***,tool wear and vibration are the bottlenecks in the milling process of aviation aluminum *** machining accuracy and surface quality of aluminum alloy milling depend on the cutting parameters,material mechanical properties,machine tools,and other *** particular,milling force is the crucial factor to determine material removal and workpiece surface ***,establishing the prediction model of milling force is important and difficult because milling force is the result of multiparameter coupling of process *** research progress of cutting force model is reviewed from three modeling methods:empirical model,finite element simulation,and instantaneous milling force *** problems of cutting force modeling are also *** view of these problems,the future work direction is proposed in the following four aspects:(1)high-speed milling is adopted for the thin-walled structure of large aviation with large cutting depth,which easily produces high residual *** residual stress should be analyzed under this particular condition.(2)Multiple factors(e.g.,eccentric swing milling parameters,lubrication conditions,tools,tool and workpiece deformation,and size effect)should be considered comprehensively when modeling instantaneous milling forces,especially for micro milling and complex surface machining.(3)The database of milling force model,including the corresponding workpiece materials,working condition,cutting tools(geometric figures and coatings),and other parameters,should be established.(4)The effect of chatter on the prediction accuracy of milling force cannot be ignored in thin-walled workpiece milling.(5)The cutting force of aviation aluminum alloy milling under the condition of minimum quantity lubrication(mql)and nanofluid mql should be predicted.

关键词： milling Aluminum alloy Force model Empirical model Finite element model Instantaneous milling force model

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milling surface roughness for 7050 aluminum alloy cavity influenced by nozzle position of nanofluid minimum quantity lubrication

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Chinese Journal of Aeronautics 2021年第6期34卷 33-53页

作者： Zhenjing DUAN Changhe LI Yanbin ZHANG Lan DONG Xiufang BAI Min YANG Dongzhou JIA Runze LI Huajun CAO Xuefeng XU School of Mechanical and Automotive Engineering Qingdao University of TechnologyQingdao 266520China School of Mechanical and Electrical Engineering Qingdao Binhai UniversityQingdao 266555China School of Mechanical Engineering Inner Mongolia University for NationalitiesTongliao 028000China Department of Biomedical Engineering University of Southern CaliforniaCA90089-1111 Los AngelesU.S.A. State Key Laboratory Mechanical Transmiss Chongqing UniversityChongqing 400044China Zhejiang University of Technology Hangzhou 310032China

In nanofluid minimum quantity lubrication(NMQL)milling of aviation aluminum alloy,it is the bottleneck problem to adjust the position parameters(target distance,incidence angle,and elevation angle)of the nozzle to improve the surface roughness of milling,which has large and uncontrollable *** this paper,the influence law of milling cutter speed,helical angle,and cavity shape on the flow field around the milling cutter was studied,and the optimal nozzle profile parameters were *** 7050 aluminum alloy as the workpiece material,the milling experiment of the NMQL cavity was conducted by utilizing cottonseed oil-based Al2 O3 *** show that the high velocity of the surrounding air flow field and the strong gas barrier could be attributed to high rotating velocities of the milling *** incidence angle of the nozzle was consistent with the helical angle of the milling cutter,the target distance was appropriate at 25–30 mm,and the elevation angle was suitable at 60°–65°.The range and variance analyses of the signal-to-noise ratio of milling force and roughness were performed,and the chip morphology was observed and *** results show that the optimal combination of nozzle position parameters was the target distance of 30 mm,the incidence angle of 35°,and the elevation angle of 60°.Among these parameters,target distance had the largest impact on cutting performance with a contribution rate of more than 55%,followed by incidence angle and elevation contribution *** by orthogonal experiment revealed that the nozzle position parameters were appropriate,and Ra(0.087 lm)was reduced by 30.4%from the maximum value(0.125 lm).Moreover,Rsm(0.05 mm)was minimum,which was 36%lower than that of the seventh group(Rsm=0.078 mm).

关键词： 7050 aluminum alloy milling milling force Nanofluid minimum quantity lubrication Nozzle position Orthogonal experimental Roughness SNR

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milling Machinability of TiC Particle and TiB Whisker Hybrid Reinforced Titanium Matrix Composites

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Transactions of Nanjing University of Aeronautics and Astronautics 2017年第4期34卷 363-371页

作者： Huan Haixiang Xu Jiuhua Su Honghua Ge Yingfei Liang Xinghui College of Mechanical and Electrical Engineering Nanjing University of Aeronautics and Astronautics School of Mechanical Engineering Yancheng Institute of Technology School of Mechanical Engineering Nanjing Institute of Technology Shanghai Institute of Aerospace Precision Machinery

The milling machinabilities of titanium matrix composites were comprehensively evaluated to provide a theoretical basis for cutting parameter determination. Polycrystalline diamond （PCD） tools with different grain sizes and geometries, and carbide tools with and without coatings were used in the experiments. milling forces, milling temperatures, tool lifetimes, tool wear, and machined surface integrities were investigated. The PCD tool required a primary cutting force 15 % smaller than that of the carbide tool, while the uncoated carbide tool required a primary cutting force 10% higher than that of the TiA1N-eoated tool. A cutting force of 300 N per millimeter of the cutting edge （300 N/mm） was measured. This caused excessive tool chipping. The cutting temperature of the PCD tool was 20%-30% lower than that of the carbide tool, while that of the TiA1N-coated tool was 12% lower than that of the uncoated carbide tool. The cutting temperatures produced when using water-based cooling and minimal quantity lubrication （MQL） were reduced by 100 ~C and 200 ~C, compared with those recorded with dry cutting, respectively. In general, the PCD tool lifetimes were 2--3 times longer than the carbide tool lifetimes. The roughness Ra of the machined surface was less than 0.6μm, and the depth of the machined surface hardened layer was in the range of 0.15-0.25 mm for all of the PCD tools before a flank wear land of 0.2 mm was reached. The PCD tool with a 0.8 mm tool nose radius, 0% rake angle, 10% flank angle, and grain size of （30＋2） μm exhibited the best cutting performance. For this specific tool, a lifetime of 16 rain can be expected.

关键词： titanium matrix composites milling machinability cutting forces cutting temperature tool lifetime and tool wear surface integrity

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milling degree affects the fermentation properties of rice:perspectives from the composition of nutrients and gut microbiota via in vitro fermentation

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Food Science and Human Wellness 2024年第3期13卷 1578-1588页

作者： Yu Zhang Fan Li Shutong Pan Bing Bai Kai Huang Sen Li Hongwei Cao Tian Xie Jian Xie Xiao Guan School of Health Science and Engineering University of Shanghai for Science and TechnologyShanghai 200093China National Grain Industry(Urban Grain and Oil Security)Technology Innovation Center Shanghai 200093China Nutrition&Health Research Institute Co.Ltd. COFCO CorporationBeijing 102209China China Grain Wuhan Scientific Research&Design Institute Co.Ltd. Wuhan 430079China

Fermentation substrates of rice with different milling degrees(MDs) were prepared and fermented with human feces to compare their fermentation properties and effects on gut *** 0s,MD 5s and MD 60s represented brown rice,moderately-milled rice and white rice,*** in vitro fermentation,the MD 5s group showed higher starch utilization,compared with the MD 0s and 60s groups evaluated by Fourier transform infrared spectrometer,and confocal laser scanning *** of fermentation substrates of rice with different MDs on gut microbiota were evaluated by 16S rDNA *** the sample groups reduced the pH and produced short-chain fatty acids(SCFAs) and branched-chain fatty *** MD 5s group exhibited higher α-diversity than the MD 0s and 60s *** of Phascolarctobacterium,Blautia and norank_f_Ruminococcaceae were higher in the MD 0s and 5s groups,compared with the MD 60s *** bacteria were also positively correlated with the SCFAs production via Spearman correlation *** vitro culture assay revealed that fermentation substrates of MD 0s and 5s promoted the growth of two probiotics(Akkermansia muciniphila and Bifidobacterium adolescentis).Our results showed that moderate milling might be an appropriate way to produce rice products with richer nutrients and better fermentation properties.

关键词： Rice processing milling Whole grains Gut microbiota

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Time-domain modeling of a cutter exiting a workpiece in the slot milling process

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Chinese Journal of Aeronautics 2016年第6期29卷 1852-1858页

作者： Luo Ming Mei Jiawei Zhang Dinghua Key Laboratory of Contemporary Design and Integrated Manufacturing Technology Ministry of EducationNorthwestern Polytechnical University Machining and Condition Monitoring Group Faculty of Engineering University of Nottingham

In a milling operation, there must be processes of a cutter entering and exiting the workpiece boundary. The cutter exit is usually in the feed direction and the dynamic response is different from that in the normal cutting process. This paper presents a new time-domain modeling of mechanics and dynamics of the cutter exit process for the slot milling process. The cutter is assumed to exit the workpiece for the first time with one tooth right in the feed direction. The dynamic chip thickness is summed up along the feed direction and compared with the remaining workpiece length in the feed direction to judge whether the cutter is ready to exit the workpiece or not. The developed model is then used for analyzing the cutting force and machining vibration in the cutter exit *** developed mathematical model is experimentally validated by comparing the simulated forces and vibrations against the measured data collected from real slotting milling tests. The study shows that stable cutting parameters cannot guarantee stable cutting in a cutter exit process and further study can be performed to control the vibration amplitude in this specific process.

关键词： Cutting force Chip thickness Dynamic stability Machining milling Vibration

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Four-axis trochoidal toolpath planning for rough milling of aero-engine blisks

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Chinese Journal of Aeronautics 2019年第8期32卷 2009-2016页

作者： Ming LUO Ce HAH Hafiz M.HAFEEZ Key Laboratory of Contemporary Design and Integrated Manufacturing Technology(Northwestern Polytechnical University) Ministry of EducationXi’an 710072China Beijing Jingdiao Group Co. Ltd.Beijing 102308China

The Blade Integrated Disk(Blisk) is one of the key components in the aero-engine, it is generally manufactured by the multi-axis milling and almost 90% raw materials are removed. To avoid the full immersion of a cutter in the rough machining of a blisk channel, the trochoidal milling is a promising strategy since it can keep a small immersion angle in the rough milling process while maintaining the high machining efficiency. However, while toolpaths are being planned for the trochoidal milling process, the conventional methods are mainly for the planar machining area with fixed tool orientations, which cannot be used for complex channels where the multi-axis machining should be employed. To this end, this paper presents a four-axis trochoidal toolpath planning method with a ball-end cutter, and thus the blisk channel can be machined *** this to happen, the trochoidal paths are planned in the parametric domain and then mapped into the physical domain, with tool orientations controlled by the quaternion interpolation method to have smooth tool movement along the toolpaths. Both geometric simulation and physical milling experiments of the proposed method have convincingly demonstrated the validation of the proposed method.

关键词： Aero-engine Blisk Machining Toolpath planning Trochoidal milling

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Enhanced photocatalytic activity of Gd3+ doped TiO2 and Gd2O3 modified TiO2 prepared via ball milling method

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Journal of Rare Earths 2019年第8期37卷 845-852,I0002页

作者： Di Wu Chen Li Dashuai Zhang Lili Wang Xiaopeng Zhang Zaifeng Shi Qiang Lin Key Laboratory of Water Pollution Treatment&Resource Reuse Hainan Normal UniversityHaikou 571158China College of Chemistry and Chemical Engineering Hainan Normal UniversityHaikou 571158China State Key Laboratory of Pollution Control and Resource Reuse Nanjing UniversityNanjing 210043China

Gd^3+/TiO2 and Gd2O3/TiO2 nanoparticles were prepared by ball milling *** effects of Gd^3+ion and Gd2O3 on the structure and optical property of TiO2 were studied by XRD and UV-vis *** surface area was determined by Brunauer-Emmett-Teller(BET)*** morphology and elemental composition were characterized by *** was used to determine the surface compositions and chemical character of *** sample sizes and microstructures were observed by *** photocatalytic activities of TiO2 nanoparticles modified with rare earth metal gadolinium(Gd^3+ion or Gd2O3)were evaluated by degradation of methylene blue(MB)under UV *** results indicate that 2,5 mol%Gd^3+/TiO2 shows the best photocatalytic activity compared with Gd2O3/TiO2 and pure *** existence of gadolinium can exhibit the aggregation and induce lattice distortion of TiO2 obtained from XRD,SEM and TEM *** band gap energy of 2.5 mol%Gd^3+/TiO2 decreases to3.07 eV and it leads to visible light absorption response which can be seen from UV-vis absorption *** surface area of 2.5 mol%Gd^3+/TiO2 equals to 85.8 m^2/g and average crystal size is 21.1 *** and XPS analyses reveal that gadolinium can be introduced either into TiO2 lattice or adsorbed on the surface of *** content of surface OH groups in 2.5 mol%Gd^3+/TiO2 is 50,88%(1.55 times higher than that of pure TiO2)and the content of lattice oxygen decreases to 11.26%.The MB(25 mg/L)degradation reaction rate constants of 2,5 mol%Gd^3+/TiO2,0.5 mol%Gd2O3/TiO2 and pure TiO2 were0.0713,0.0588 and 0.0263 min^-1,*** degradation rates of rhodamine B(30 mg/L)in 60 min are 97,9%,90.1%and 84.6%for 2,5 mol%Gd^3+/TiO2,0.5 mol%Gd2O3/TiO2 and pure TiO2,respectively.

关键词： Ball milling method Rare earth Gadolinium TiO2 Methylene blue

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Microstructure evolution and interface structure of Al-40 wt% Si composites produced by high-energy ball milling

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Journal of Materials Science & Technology 2019年第4期35卷 512-519页

作者： Yuanyuan Chen Zhangping Hu Yifei Xu Jiangyong Wang Peter Schützendübe Yuan Huang Yongchang Liu Zumin Wang School of Materials Science and Engineering Tianjin University Department of Physics Shantou University Max Planck Institute for Intelligent Systems

High silicon content Al-Si composites with a composition of Al-40 wt% Si were fabricated via a highenergy ball milling method. The microstructure evolution of Al-40 wt% Si milled powders and sintered composites has been thoroughly studied by scanning electron microscopy, X-ray diffraction, energydispersive spectrometry and high-resolution transmission electron microscopy. The mechanism of ball milling Al-40 wt% Si powders has been disclosed in detail: fracture mechanism dominating in the early stages, followed by the agglomeration mechanism, finally reaching the balance between the fragments and the agglomerates. It has been found that the average particle sizes of mixed Al-Si powders can be refined to the nanoscale, and the crystallite sizes of Al and Si have been reduced to 10nm and 62nm upon milling for 2h–50h, respectively. The finally formed Al-Si interfaces after ball milling for 50h are wellcohesive. A dense and homogenous Al-40 wt% Si composite have been achieved by solid-state sintering at550?C. The results thus provide an effective support for producing bulk nanostructured Al-Si composites.

关键词： Al-Si composites Interface structure High-energy ball milling Nanocrystalline powders

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Bone milling:On Monitoring Cutting State and Force Using Sound Signals

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Chinese Journal of Mechanical Engineering 2022年第3期35卷 123-134页

作者： Zhenzhi Ying Liming Shu Naohiko Sugita Department of Mechanical Engineering School of EngineeringThe University of Tokyo7‑3‑1 HongoBunkyo‑kuTokyo 1138656Japan Research into Artifacts Center for Engineering School of EngineeringThe University of Tokyo7‑3‑1 HongoBunkyo‑kuTokyo 1138656Japan

Efficient monitoring of bone milling conditions in orthopedic and neurosurgical surgery can prevent tissue,bone,and tool damage,and reduce surgery *** researches are mainly focused on recognizing the cutting state using force ***,the force signal during the milling process is difficult and expensive to *** this study,a neural network-based method is proposed to recognize the cutting state and force during the bone milling process using sound *** modeling of the cutting force is performed to capture the relationship between the cutting force and the depth of cut in the bone milling *** force model is used to calibrate the training data to improve the recognition *** package transform is used for signal processing to understand bone-cutting phenomena using sound *** proposed system succeeds to monitor the bone milling process to reduce the surgical *** on standard bone specimens and vertebrae also indicate that the proposed approach has considerable potential for use in computer-assisted and robot-assisted bone-cutting systems used in various types of surgery.

关键词： Cutting state Force milling Artificial neural network

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Tool wear mechanisms in axial ultrasonic vibration assisted milling in-situ TiB2/7050Al metal matrix composites

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Advances in Manufacturing 2020年第2期8卷 252-264页

作者： Xiao-Fen Liu Wen-Hu Wang Rui-Song Jiang Yi-Feng Xiong Kun-Yang Lin School of Mechanical Engineering Northwestern Polytechnical UniversityXi'an 710072People's Republic of China School of Aeronautics and Astronautics Sichuan UniversityChengdu 610065People's Republic of China

The in-situ TiB2 particle reinforced aluminum matrix composites are materials that are difficult to machine,owing to hard ceramic particles in the *** the milling process,the polycrystalline diamond(PCD)tools are used for machining these materials instead of carbide cutting tools,which significantly increase the machining *** this study,ultrasonic vibration method was applied for milling in-situ TiB2/7050A1 metal matrix composites using a TiAIN coated carbide end milling *** completely understand the tool wear mechanism in ultrasonic-vibration assisted milling(UAM),the relative motion of the cutting tool and interaction of workpiecetool-chip contact interface was analyzed in ***,a comparative experimental study with and without ultrasonic vibration was carried out to investigate the infuences of ultrasonic vibration and cutting parameters on the cutting force,tool life and tool wear *** results show that the motion of the cutting tool relative to the chip changes periodically in the helical direction and the separation of tool and chip occurs in the transverse direction in one vibration period,in ultrasonic vibration assisted cutting.I arge instantaneous acceleration can be obtained in axial ultrasonic vibration *** cutting force in axial direction is significantly reduced by 42%-57%,40%--57%and 44%-54%,at different cutting speeds,feed rates and cutting depths,respectively,compared with that in conventional ***,the tool life is prolonged approximately 2--5 times when the ultrasonic vibration method is *** tool wear pattern microcracks are only found in *** might be of great importance for future research in order to understand the cutting mechanisms in UAM of in-situ TiB2/7050A1 metal matrix composites.

关键词： Aluminum matrix composites Ultrasonic vibration milling Cutting force Tool wear

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