Experimental evaluation of surface generation and force time-varying characteristics of curvilinear grooved micro end mills fabricated by EDM

Sun, Yangyang; Jin, Liya; Gong, Yadong; Wen, Xuelong; Yin, Guoqiang; Wen, Quan; Tang, Benjia

doi:10.1016/j.jmapro.2021.11.049

Cited by 121 publications

(19 citation statements)

References 31 publications

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“…The grinding process of titanium alloy [35], superalloy [36,37], high-strength steel [38], composite material [39,40], and other difficult-tomachine materials [41,42] has the serious problems of heavy grinding force, high temperature, and severe wheel wear or clogging [43][44][45]. The aforementioned issues in MQL grinding must be addressed as soon as possible [46][47][48]. Nano-enhanced biolubricants, which are prepared by adding nanoparticles in the biolubricant, are expected to improve grindability and meet the demand for green manufacturing [49][50][51].…”

Section: Introductionmentioning

confidence: 99%

Comparative assessment of force, temperature, and wheel wear in sustainable grinding aerospace alloy using biolubricant

Cui

Zhang

et al. 2022

Front. Mech. Eng.

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The substitution of biolubricant for mineral cutting fluids in aerospace material grinding is an inevitable development direction, under the requirements of the worldwide carbon emission strategy. However, serious tool wear and workpiece damage in difficult-to-machine material grinding challenges the availability of using biolubricants via minimum quantity lubrication. The primary cause for this condition is the unknown and complex influencing mechanisms of the biolubricant physicochemical properties on grindability. In this review, a comparative assessment of grindability is performed using titanium alloy, nickel-based alloy, and high-strength steel. Firstly, this work considers the physicochemical properties as the main factors, and the antifriction and heat dissipation behaviours of biolubricant in a high temperature and pressure interface are comprehensively analysed. Secondly, the comparative assessment of force, temperature, wheel wear and workpiece surface for titanium alloy, nickel-based alloy, and high-strength steel confirms that biolubricant is a potential replacement of traditional cutting fluids because of its improved lubrication and cooling performance. High-viscosity biolubricant and nano-enhancers with high thermal conductivity are recommended for titanium alloy to solve the burn puzzle of the workpiece. Biolubricant with high viscosity and high fatty acid saturation characteristics should be used to overcome the bottleneck of wheel wear and nickel-based alloy surface burn. The nano-enhancers with high hardness and spherical characteristics are better choices. Furthermore, a different option is available for high-strength steel grinding, which needs low-viscosity biolubricant to address the debris breaking difficulty and wheel clogging. Finally, the current challenges and potential methods are proposed to promote the application of biolubricant.

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Section: Introductionmentioning

confidence: 99%

Comparative assessment of force, temperature, and wheel wear in sustainable grinding aerospace alloy using biolubricant

Cui

Zhang

et al. 2022

Front. Mech. Eng.

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“…Smartlab9KW X-ray diffraction was used to analyze the phase of the oxidation products on the surface of the sample. Zeiss Ultra 55 scanning electron microscope [ 21 ] was used to observe the oxidation morphology and cross-section morphology of the sample. JEOL-JXA-8530F field emission electron probe was used to observe the distribution of elements on the cross-section of the coating.…”

Section: Methodsmentioning

confidence: 99%

Effect of Pre-Oxidation on High-Temperature Oxidation Behavior of Al-Si Coating on Nickel-Based Superalloy

et al. 2022

Materials

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Under the condition of long-time high-temperature oxidation, oxidation in Al-Si coating will lead to degradation of the coating. To solve this problem, the Al-Si coating was treated before the oxidation experiment at different pre-oxidation temperatures and times. The structure, morphology and element distribution of the oxide film were characterized by XRD, SEM and EPMA, and the oxidation kinetics curves were drawn. The results show that the oxidation resistance of the pre-oxidized samples is improved in the process of constant temperature oxidation at 1000 °C. When the pre-oxidation temperature is set at 950 °C, the mass gain of the samples is the lowest, and the accelerated decomposition of Cr2O3 caused by high pre-oxidation temperature is avoided. After oxidation for 300 h, the oxide film on the surface is still continuous and dense without peeling. The samples pre-oxidized at 950 °C for 7 h show the best oxidation resistance in a 1000 °C constant temperature oxidation process, more α-Al2O3 oxides are generated on the coating surface and the element diffusion between the matrix and the coating caused by overly long oxidation time is avoided.

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“…The results show that when the radial depth of cut and feed increase, the helix angle has less and less influence on the cutting force coefficient. Sun et al 29 attempted to create curvilinear groove microtexturing on the backside of a double helix micro end mill by electrical discharge machining (EDM). The surface generation mechanism, time-varying characteristics of force, specific milling energy, chip volume, and tool wear pattern of micro-end mills with curved grooves in dry micro-milling are revealed.…”

Section: Chatter Predictionmentioning

confidence: 99%

Prediction, detection, and suppression of regenerative chatter in milling

Liang

Liu

et al. 2022

Advances in Mechanical Engineering

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In metal cutting processing, especially in the processing of low-rigidity workpieces, chatter is a key factor affecting many aspects such as surface quality, processing efficiency and tool life. The academic research on chatter mainly focuses on three directions: chatter prediction, real-time detecting, and chatter suppression. With the continuous development of machining toward intelligence, the hot spots and trends of chatter research are also constantly changing. Therefore, an in-depth and systematic summary of the current situation of chatter research is urgently needed. On this basis, it is of great significance to realize the prediction of the hot spots and trends of chatter research. This article summarizes the research status from three aspects of chatter prediction, detecting and suppression, and points out the advantages and limitations of current chatter research. After in-depth discussion, this article also looks forward to the trend of chatter research. The hot spots of chatter research will focus on the following points: (1) Chatter research methods and means based on data-driven. (2) Integrated data collection, processing and decision-making methods. (3) Chatter detecting unit and chatter suppression unit are integrated in the smart spindle. (4) The chatter mechanism and detecting research of robot milling.

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Experimental evaluation of surface generation and force time-varying characteristics of curvilinear grooved micro end mills fabricated by EDM

Cited by 121 publications

References 31 publications

Comparative assessment of force, temperature, and wheel wear in sustainable grinding aerospace alloy using biolubricant

Comparative assessment of force, temperature, and wheel wear in sustainable grinding aerospace alloy using biolubricant

Effect of Pre-Oxidation on High-Temperature Oxidation Behavior of Al-Si Coating on Nickel-Based Superalloy

Prediction, detection, and suppression of regenerative chatter in milling

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