Energy field-assisted high-speed dry milling green machining technology for difficult-to-machine metal materials

Abstract

Energy field-assisted machining technology has the potential to overcome the limitations of machining difficult-to-machine metal materials, such as poor machinability, low cutting efficiency, and high energy consumption. High-speed dry milling has emerged as a typical green processing technology due to its high processing efficiency and avoidance of cutting fluids. However, the lack of necessary cooling and lubrication in high-speed dry milling makes it difficult to meet the continuous milling requirements for difficult-to-machine metal materials. The introduction of advanced energy-field-assisted green processing technology can improve the machinability of such metallic materials and achieve efficient precision manufacturing, making it a focus of academic and industrial research. In this review, the characteristics and limitations of high-speed dry milling of difficult-to-machine metal materials, including titanium alloys, nickel-based alloys, and high-strength steel, are systematically explored. The laser energy field, ultrasonic energy field, and cryogenic minimum quantity lubrication energy fields are introduced. By analyzing the effects of changing the energy field and cutting parameters on tool wear, chip morphology, cutting force, temperature, and surface quality of the workpiece during milling, the superiority of energy-field-assisted milling of difficult-to-machine metal materials is demonstrated. Finally, the shortcomings and technical challenges of energy-field-assisted milling are summarized in detail, providing feasible ideas for realizing multi-energy field collaborative green machining of difficult-to-machine metal materials in the future.

Computer-aided design system for the end mill made by laser ablation and grinding

“…Movement 𝑥𝑦 the cutter tooth is formed by a rotational movement at an angle 𝜃 and an associated translational movement at a distance the cutting tooth is described by equation (1,2).…”

“…High-speed multi-axis machining is one of the most high-tech areas of engineering. High machining tools require high thermal loads, rotating stress levels, severe heat dissipation conditions, and high chip shapes [1][2][3][4][5][6].…”

Nanofluids Minimal Quantity Lubrication Machining: From Mechanisms to Application

“…Modern technology has more and more higher requirements for the efficiency and technology of workpiece production [219]. However, conventional machining techniques face formidable challenges when dealing with difficult to machine materials due to their unique properties and behavior [220]. Machining these materials often encounters challenges such as high flank wear, poor surface finish, work hardening, thermal deformation, and a low machinability index [221].…”

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

“…Difficult-to-cut materials in the aerospace community can be classified into three categories according to the main properties that determine the performance of the parts or components. Materials in the first category are characterized by excellent strength and high toughness, such as titanium alloys, hightemperature alloys, high-and ultrahigh-strength steels, and stainless steels [4][5][6][7][8]. These materials are used in aerospace parts or components operated under high stress or high temperature, including aeroengine blisks and turbine blades [9][10][11][12].…”