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

• Published in: Chinese journal of mechanical engineering Vol. 34; no. 1; pp. 1 - 35
• Main Authors: Duan, Zhenjing, Li, Changhe, Ding, Wenfeng, Zhang, Yanbin, Yang, Min, Gao, Teng, Cao, Huajun, Xu, Xuefeng, Wang, Dazhong, Mao, Cong, Li, Hao Nan, Kumar, Gupta Munish, Said, Zafar, Debnath, Sujan, Jamil, Muhammad, Ali, Hafiz Muhammad
• Format: Journal Article
• Language: English
• Published: Singapore Springer Singapore 01-12-2021; Springer Nature B.V; SpringerOpen
• Edition: English ed.
• Subjects: Accuracy; Aluminum alloy; Aluminum alloys; Aluminum base alloys; Aviation; Cutting force; Cutting parameters; Deformation effects; Electrical Machines and Networks; Electronics and Microelectronics; Empirical analysis; Empirical model; Engineering; Engineering Thermodynamics; Finite element method; Finite element model; Force model; Heat and Mass Transfer; High speed machining; Instantaneous milling force model; Instrumentation; Lubrication; Machine tools; Machines; Manufacturing; Mathematical models; Mechanical Engineering; Mechanical properties; Milling; Modelling; Nanofluids; Overview; Power Electronics; Prediction models; Processes; Residual stress; Review; Size effects; Space stations; Surface properties; Theoretical and Applied Mechanics; Thin wall structures; Tool wear; Workpieces; Finite element model; Empirical model; Milling; Force model; Aluminum alloy; Instantaneous milling force model
• ISSN: 1000-9345; 2192-8258
• DOI: 10.1186/s10033-021-00536-9

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.