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

Chinese Journal of Mechanical Engineering

Cong Mao¹  Zafar Said²  Wenfeng Ding³  Muhammad Jamil³  Gupta Munish Kumar⁴  Xuefeng Xu⁵  Sujan Debnath⁶  Hafiz Muhammad Ali⁷  Hao Nan Li⁸  Zhenjing Duan⁹  Min Yang⁹  Teng Gao⁹  Yanbin Zhang⁹  Changhe Li⁹  Dazhong Wang^1,10  Huajun Cao^1,11 

[1] College of Automotive and Mechanical Engineering, Changsha University of Science and Technology;College of Engineering, University of Sharjah;College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics;Key Lab High Efficiency and Clean Mech Manufacture, Shandong University;Key Laboratory of Special Purpose Equipment and Advanced Processing Technology, Ministry of Education & Zhejiang Province, Zhejiang University of Technology;Mechanical Engineering Department, Curtin University;Mechanical Engineering Department, King Fahd University of Petroleum and Minerals;School of Aerospace, University of Nottingham Ningbo China;School of Mechanical and Automotive Engineering, Qingdao University of Technology;School of Mechanical and Automotive Engineering, Shanghai University of Engineering Science;State Key Laboratory Mechanical Transmiss, Chongqing University;

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

DOI  :  10.1186/s10033-021-00536-9

来源: DOAJ

【 摘 要 】

Abstract Aluminum alloy is the main structural material of aircraft, launch vehicle, spaceship, and space station and is processed by milling. However, tool wear and vibration are the bottlenecks in the milling process of aviation aluminum alloy. The machining accuracy and surface quality of aluminum alloy milling depend on the cutting parameters, material mechanical properties, machine tools, and other parameters. In particular, milling force is the crucial factor to determine material removal and workpiece surface integrity. However, establishing the prediction model of milling force is important and difficult because milling force is the result of multiparameter coupling of process system. The research progress of cutting force model is reviewed from three modeling methods: empirical model, finite element simulation, and instantaneous milling force model. The problems of cutting force modeling are also determined. In 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 stress. The 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.

【 授权许可】

Unknown