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

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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.

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  • 30 March 2023

    The issue number has been corrected

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Acknowledgements

This study was financially supported by the National Natural Science Foundation of China (Grant Nos. 51975305, 51905289, 52105457, and 52105264), the National Key R&D Program of China (Grant No. 2020YFB2010500), the Key Projects of Shandong Natural Science Foundation, China (Grant Nos. ZR2020KE027, ZR2020ME158, and ZR2021QE116), the Major Science and Technology Innovation Engineering Projects of Shandong Province, China (Grant No. 2019JZZY020111), the Source Innovation Project of Qingdao West Coast New Area, China (Grant Nos. 2020-97 and 2020-98).

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Authors and Affiliations

  1. School of Mechanical and Automotive Engineering, Qingdao University of Technology, Qingdao, 266520, China

    Zhenjing Duan, Changhe Li, Min Yang & Teng Gao

  2. School of Mechanical Engineering, Dalian University of Technology, Dalian, 116024, China

    Zhenjing Duan & Xin Liu

  3. State Key Laboratory of Ultra-precision Machining Technology, Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Hong Kong, 999077, China

    Yanbin Zhang

  4. Department of Biomedical Engineering, University of Southern California, Los Angeles, CA, 90089-1111, USA

    Runze Li

  5. College of Engineering, University of Sharjah, Sharjah, 27272, United Arab Emirates

    Zafar Said

  6. Mechanical Engineering Department, Curtin University, Miri, 98009, Malaysia

    Sujan Debnath

  7. Department of Mechanical Engineering, IK Gujral Punjab Technical University, Punjab, 144603, India

    Shubham Sharma

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  1. Zhenjing Duan
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  2. Changhe Li
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Duan, Z., Li, C., Zhang, Y. et al. Mechanical behavior and semiempirical force model of aerospace aluminum alloy milling using nano biological lubricant. Front. Mech. Eng. 18, 4 (2023). https://doi.org/10.1007/s11465-022-0720-4

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