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

Zhenjing Duan, Changhe Li, Wenfeng Ding, Yanbin Zhang, Min Yang, Teng Gao, Huajun Cao, Xuefeng Xu, Dazhong Wang, Cong Mao, Hao Nan Li, Gupta Munish Kumar, Zafar Said, Sujan Debnath, Muhammad Jamil, Hafiz Muhammad Ali

Research output: Journal PublicationReview articlepeer-review

74 Citations (Scopus)

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.

Original languageEnglish
Article number18
JournalChinese Journal of Mechanical Engineering (English Edition)
Volume34
Issue number1
DOIs
Publication statusPublished - Dec 2021

Keywords

  • Aluminum alloy
  • Empirical model
  • Finite element model
  • Force model
  • Instantaneous milling force model
  • Milling

ASJC Scopus subject areas

  • Mechanical Engineering
  • Industrial and Manufacturing Engineering

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