Mechanical behavior and semiempirical force model of aerospace aluminum alloy milling using nano biological lubricant

doi:10.1007/s11465-022-0720-4

Front. Mech. Eng.

2023, Vol. 18

Issue (1) : 4 https://doi.org/10.1007/s11465-022-0720-4

RESEARCH ARTICLE

Mechanical behavior and semiempirical force model of aerospace aluminum alloy milling using nano biological lubricant

Zhenjing DUAN^1,², Changhe LI¹(

), Yanbin ZHANG³(

), Min YANG¹, Teng GAO¹, Xin LIU², Runze LI⁴, Zafar SAID⁵, Sujan DEBNATH⁶, Shubham SHARMA⁷

¹. School of Mechanical and Automotive Engineering, Qingdao University of Technology, Qingdao 266520, China
². School of Mechanical Engineering, Dalian University of Technology, Dalian 116024, China
³. State Key Laboratory of Ultra-precision Machining Technology, Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Hong Kong 999077, China
⁴. Department of Biomedical Engineering, University of Southern California, Los Angeles, CA 90089-1111, USA
⁵. College of Engineering, University of Sharjah, Sharjah 27272, United Arab Emirates
⁶. Mechanical Engineering Department, Curtin University, Miri 98009, Malaysia
⁷. Department of Mechanical Engineering, IK Gujral Punjab Technical University, Punjab 144603, India

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Abstract

Aerospace aluminum alloy is the most used structural material for rockets, aircraft, spacecraft, and space stations. The deterioration of surface integrity of dry machining and the insufficient heat transfer capacity of minimal quantity lubrication have become the bottleneck of lubrication and heat dissipation of aerospace aluminum alloy. However, the excellent thermal conductivity and tribological properties of nanofluids are expected to fill this gap. The traditional milling force models are mainly based on empirical models and finite element simulations, which are insufficient to guide industrial manufacturing. In this study, the milling force of the integral end milling cutter is deduced by force analysis of the milling cutter element and numerical simulation. The instantaneous milling force model of the integral end milling cutter is established under the condition of dry and nanofluid minimal quantity lubrication (NMQL) based on the dual mechanism of the shear effect on the rake face of the milling cutter and the plow cutting effect on the flank surface. A single factor experiment is designed to introduce NMQL and the milling feed factor into the instantaneous milling force coefficient. The average absolute errors in the prediction of milling forces for the NMQL are 13.3%, 2.3%, and 7.6% in the x-, y-, and z-direction, respectively. Compared with the milling forces obtained by dry milling, those by NMQL decrease by 21.4%, 17.7%, and 18.5% in the x-, y-, and z-direction, respectively.

Keywords milling force nanofluid minimum quantity lubrication aerospace aluminum alloy nano biological lubricant

Corresponding Author(s): Changhe LI,Yanbin ZHANG

Just Accepted Date: 18 July 2022 Issue Date: 16 February 2023

Cite this article:

Zhenjing DUAN,Changhe LI,Yanbin ZHANG, et al. Mechanical behavior and semiempirical force model of aerospace aluminum alloy milling using nano biological lubricant[J]. Front. Mech. Eng., 2023, 18(1): 4.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-022-0720-4
https://academic.hep.com.cn/fme/EN/Y2023/V18/I1/4

Fig.1 Schematic of milling thickness.

Fig.2 Schematic of micro-unit milling force.

Fig.3 Schematic of coordinate system transformation.

Fig.4 Boundary conditions of milling force model.

Fig.5 Experimental equipment of aerospace aluminum alloy milling force.

Tab.1 Chemical composition of workpieces

Tab.2 Mechanical properties of workpieces

Tab.3 Characteristics of cottonseed oil

Tab.4 Fatty acid of cottonseed oil

Tab.5 Properties of Al₂O₃ nanoparticles

Fig.6 Nanofluid preparation equipment for milling force experiment.

Tab.6 Experimental milling parameters

Tab.7 Test parameters for milling force coefficient identification

No.	NMQL			Dry
No.	$F x ¯$ /N	$F y ¯$ /N	$F z ¯$ /N	$F x ¯$ /N	$F y ¯$ /N	$F z ¯$ /N
1	42.40	−51.05	−26.42	61.57	−69.91	−31.19
2	59.79	−73.02	−38.24	80.42	−88.79	−42.95
3	78.28	−89.42	−50.12	99.11	−104.42	−55.32

Tab.8 Experimental result of milling force

Tab.9 Instantaneous milling force coefficients

Fig.7 Flowchart of instantaneous milling force simulation.

Fig.8 Comparison of calculated and measured milling forces: (a) dry milling force waveform, (b) dry average milling force, (c) nanofluid minimal quantity lubrication milling force waveform, and (d) nanofluid minimal quantity lubrication average milling force.

Fig.9 Comparison of dry and NMQL milling forces. NMQL: nanofluid minimal quantity lubrication.

Fig.10 Schematic of the molecular structure of Al₂O₃ nanoparticles.

a_p	Axial cutting depth
A(θ)	Determining whether the tool is involved in cutting
f_z	Feed speed
$F ¯ q$	Periodic average milling force per tooth
$F ¯ q c$	Coefficient component of cutting edge force
$F ¯ q e$	Component of cutting edge force
dF_a	Axial force
dF_r	Radial force
dF_t	Tangential force
dF_x,j(θ, z), dF_y,j(θ, z), dF_z,j(θ, z)	x-, y-, and z-direction forces applied to the jth micro element cutting edge, respectively
h	Instantaneous cutting thickness
j	jth cutting tooth
K_ac	Axial shearing force coefficient
K_ae	Axial edge force coefficient
K_rc	Radial shearing force coefficient
K_re	Radial edge force coefficient
K_tc	Tangential shearing force coefficient
K_te	Tangential edge force coefficient
n	Spindle speed
N	Number of milling cutter teeth
R	Diameter of the tool
t	Milling time
z_j,1	Lower axial meshing limit of the cutting part of the cutter tooth j
z_j,2	Upper axial meshing limit of the cutting part of the cutter tooth j
dz	Axial cutting height element
θ	Angular position of the tooth in the cutting
θ_ex	Cutter exit angle
θ_j	Instantaneous tooth position angle of the jth slot
θ_j(z)	Instantaneous tooth position angle
θ_p	Angle between teeth of milling cutter
θ_st	Cutter entry angle
ρ	Spiral angle of the milling cutter
ψ_a	Lag angle at the maximum cutting axial depth

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