An improved time-varying stability analysis of micro milling considering tool wear

Zhao, Guolong; Song, Jichao; Nian, Zhiwen; Xin, Lianjia; Li, Liang; He, Ning

doi:10.1016/j.jmapro.2022.10.080

Cited by 15 publications

(2 citation statements)

References 22 publications

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“…In light of the relentless advancement in high-end equipment performance and material enhancement, the machining of turbine disc slots has encountered escalating challenges. Traditional machining techniques, such as broaching and milling, struggle to meet the increasingly stringent demands for processing cost, quality, and precision, thus posing a bottleneck in the progression of aero-engine equipment performance [5]. Presently, slots machining methodologies encompass broaching, milling, grinding, wire electrochemical machining (WECM), and WEDM [6],…”

Section: Introductionmentioning

confidence: 99%

Experimental investigations on WEDM performance characteristics of FGH99 powder metallurgy superalloy

Qian,

Zhao,

et al. 2024

Preprint

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In response to challenges posed by conventional machining methods, an exploratory experimental investigation was conducted to assess the effectiveness of wire electric discharge machining (WEDM) in fabricating turbine disc slots from powder metallurgy superalloy FGH99. The present study conducted a single-factor experiment on WEDM using FGH99 alloys, with the aim of investigating the impact of different WEDM parameters on the material removal rate, surface roughness, and surface morphology. Additionally, the analysis encompassed the characterization of both the heat-affected zone and plastic deformation zone on the workpiece surface. Results show that there is a positive correlation between surface roughness and variables such as pulse width, pulse gap, servo voltage, and wire tension. Conversely, wire speed exhibits an inverse relationship with surface roughness. Notably, the impact of pulse width on surface roughness surpasses that of other parameters. Metallographic examination reveals that under the selected process parameters, while ensuring the efficiency of material removal, superior machining quality was achieved. The absence of conspicuous recast layers on the workpiece surface, with an average thickness of the plastic deformation layer measured at 3.97 µm, indicating favorable processing outcomes. The aforementioned findings provide valuable experimental insights into the WEDM process of FGH99 alloys and offer foundational engineering data for the fabrication of turbine disc slots made from this material.

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Section: Introductionmentioning

confidence: 99%

Experimental investigations on WEDM performance characteristics of FGH99 powder metallurgy superalloy

Qian,

Zhao,

et al. 2024

Preprint

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show abstract

“…The extensive utilization of cutting fluid not only escalates manufacturing expenses and impairs the ecological environment, but also poses a threat to the operator's health [2,3]. Furthermore, in metal cutting, particularly for difficult-to-cut materials, it is arduous to circumvent the necessity for cooling and lubrication in the cutting zone [4,5]. In this case, scholars have proposed a range of environmentally-friendly technologies, such as dry cutting, cryogenic cooling, and minimum quantity lubrication (MQL).…”

Section: Introductionmentioning

confidence: 99%

A novel cooling and lubrication approach: Device development and machining performance evaluation of ultrasonic vibration–assisted MQL

Zhang,

Wu,

Zhao

et al. 2024

Int J Adv Manuf Technol

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Minimum quantity lubrication (MQL) as a sustainable technology has gained popularity in addressing the conflict between environmental protection and the machining requirements during cutting processes. However, conventional MQL systems employ pneumatic atomization, resulting in the generation of oil droplets with large particle sizes and uneven distribution, eventually leading to the inadequate lubrication performance of the MQL jet. In this case, the present study employed a combination of ultrasonic atomization and MQL technique to propose a novel cooling and lubrication approach and fabricate the ultrasonic vibration-assisted MQL (UVMQL) device. Geometric parameters of the ultrasonic vibrator of this device were designed and optimized using the theoretical design and finite element simulation techniques. Additionally, the impedance and amplitude detected to evaluate the performance of the UVMQL device.Subsequently, the comparative experiments were carried out under five cooling and lubrication conditions in machining of ultra-high strength steels: dry cutting, wet cutting, high-pressure air cooling, MQL and UVMQL. Then, the machining performance of the UVMQL was discussed, in terms of cutting forces, cutting temperature, surface roughness, surface topography and chips. Results demonstrate that in comparison to MQL, UVMQL has a lower cutting force by 5.3N, leading to the formation of a more effective oil film lubrication layer. Due to the excellent penetration of fine oil droplets, UVMQL possesses a slightly higher cutting temperature than that of wet cutting by 43℃, whereas results in optimal surface roughness value and surface topography of the workpiece. Additionally, under UVMQL condition, the length of chip bonding zone is reduced by 39.8%, and the saw-tooth height of chip is decreased by 35.9% compared to dry cutting.

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Tool path optimization with stability constraints for ball-end milling cutters based on frequency domain controlling strategy

Xu,

Zhang,

Liu

et al. 2024

Int J Adv Manuf Technol

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An improved time-varying stability analysis of micro milling considering tool wear

Cited by 15 publications

References 22 publications

Experimental investigations on WEDM performance characteristics of FGH99 powder metallurgy superalloy

Experimental investigations on WEDM performance characteristics of FGH99 powder metallurgy superalloy

A novel cooling and lubrication approach: Device development and machining performance evaluation of ultrasonic vibration–assisted MQL

Tool path optimization with stability constraints for ball-end milling cutters based on frequency domain controlling strategy

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