Abstract
Energy field-assisted machining technology has the potential to overcome the limitations of machining difficult-to-machine metal materials, such as poor machinability, low cutting efficiency, and high energy consumption. High-speed dry milling has emerged as a typical green processing technology due to its high processing efficiency and avoidance of cutting fluids. However, the lack of necessary cooling and lubrication in high-speed dry milling makes it difficult to meet the continuous milling requirements for difficult-to-machine metal materials. The introduction of advanced energy-field-assisted green processing technology can improve the machinability of such metallic materials and achieve efficient precision manufacturing, making it a focus of academic and industrial research. In this review, the characteristics and limitations of high-speed dry milling of difficult-to-machine metal materials, including titanium alloys, nickel-based alloys, and high-strength steel, are systematically explored. The laser energy field, ultrasonic energy field, and cryogenic minimum quantity lubrication energy fields are introduced. By analyzing the effects of changing the energy field and cutting parameters on tool wear, chip morphology, cutting force, temperature, and surface quality of the workpiece during milling, the superiority of energy-field-assisted milling of difficult-to-machine metal materials is demonstrated. Finally, the shortcomings and technical challenges of energy-field-assisted milling are summarized in detail, providing feasible ideas for realizing multi-energy field collaborative green machining of difficult-to-machine metal materials in the future.
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Abbreviations
- B&F:
-
Back-and-forth
- CA:
-
Cold air
- CCD:
-
Central composite design
- CFD:
-
Computational fluid dynamics
- CL:
-
Conventional melting
- CM:
-
Conventional milling
- CMQL:
-
Cryogenic minimum quantity lubrication
- CMQLAM:
-
Cryogenic minimum quantity lubrication energy fieldassisted milling
- CVD:
-
Chemical vapor deposition
- DHC:
-
Double helix channel
- DSC:
-
Double straight channel
- FEM:
-
Finite element method
- HAZ:
-
heat-affected zone
- H.F:
-
High feed milling
- HM:
-
Helical milling
- HPDL:
-
High-power semiconductor laser
- HSDM:
-
High-speed dry milling
- LAM:
-
Laser-assisted milling
- LCO2:
-
Liquid carbon dioxide
- L.F:
-
Low feed milling
- LMO:
-
Local misorientation
- LS:
-
Single laser scanning
- MQL:
-
Minimum quantity lubrication
- Nd:YAG:
-
Neodymium-doped yttrium aluminum garnet
- NMQL:
-
Nanofluid minimum quantity lubrication
- NURBS:
-
Non-uniform rational B-spline
- OoW:
-
Oil-on-water
- PCBN:
-
Polycrystalline cubic boron nitride
- PVD:
-
Physical vapor deposition
- SCCO2 :
-
Supercritical carbon dioxide
- SEM:
-
Scanning electron microscope
- SLM:
-
Selective laser melting
- SSC:
-
Single straight channel
- S&T:
-
Spatial and temporal
- TAM:
-
Thermal-assisted machining
- TC4:
-
Ti−6Al−4V
- UVAM:
-
Ultrasonic vibration-assisted milling
- XRD:
-
X-ray diffraction
- A :
-
Vibration amplitude
- d L :
-
Heat source size
- f :
-
Vibration frequency
- f z :
-
Feed per tooth
- N z :
-
Number of tips
- P ei :
-
Coordinate tool point
- P li :
-
Initial coordinate point
- P L :
-
Laser power
- P Li :
-
End coordinate point
- r :
-
Radius of the cutting tool
- r c :
-
Sum of the radius of the cutting tool
- R :
-
Expected fillet radius
- Sa :
-
Average roughness
- Sq :
-
Surface root mean square roughness
- t :
-
Cutting time
- v c :
-
Cutting speed
- v f :
-
Feed speed
- V L :
-
Laser scanning speed
- x, y, z :
-
Tip displacements
- x cl :
-
Distance between the tool center and the laser heat source center
- x L :
-
Distance between spot and tool
- ω r :
-
Angular velocity of the spindle
- α i :
-
Tool radius angle
- α p :
-
Axial cutting depth
- α c :
-
Radial cut width
- β :
-
Tool rotation angle
- θ :
-
Initial phase of the vibration signal
- Δxi :
-
Distance between the initial coordinate point of the heat source and the end coordinate point
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This work was supported by the National Key R&D Program of China (Grant No. 2020YFB2010500). The authors gratefully acknowledge the reviewers and editors for their insightful comments.
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Zhang, J., Huang, X., Kang, X. et al. Energy field-assisted high-speed dry milling green machining technology for difficult-to-machine metal materials. Front. Mech. Eng. 18, 28 (2023). https://doi.org/10.1007/s11465-022-0744-9
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DOI: https://doi.org/10.1007/s11465-022-0744-9