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

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.

Graphical abstract

Keywords

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

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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).

Nomenclature

ap	Axial cutting depth
A(θ)	Determining whether the tool is involved in cutting
fz	Feed speed
{\overline{F}}_q	Periodic average milling force per tooth
{\overline{F}}_{q\mathrm{c}}	Coefficient component of cutting edge force
{\overline{F}}_{q\mathrm{e}}	Component of cutting edge force
dFa	Axial force
dFr	Radial force
dFt	Tangential force
dFx,j(θ, z), dFy,j(θ, z), dFz,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
Kac	Axial shearing force coefficient
Kae	Axial edge force coefficient
Krc	Radial shearing force coefficient
Kre	Radial edge force coefficient
Ktc	Tangential shearing force coefficient
Kte	Tangential edge force coefficient
n	Spindle speed
N	Number of milling cutter teeth
R	Diameter of the tool
t	Milling time
zj,1	Lower axial meshing limit of the cutting part of the cutter tooth j
zj,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
θex	Cutter exit angle
θj	Instantaneous tooth position angle of the jth slot
θj(z)	Instantaneous tooth position angle
θp	Angle between teeth of milling cutter
θst	Cutter entry angle
ρ	Spiral angle of the milling cutter
ψa	Lag angle at the maximum cutting axial depth

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