Energy field-assisted high-speed dry milling green machining technology for difficult-to-machine metal materials

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.

Graphical abstract

Keywords

difficult-to-machine metal material / green machining / high-speed dry milling / laser energy field-assisted milling / ultrasonic energy field-assisted milling / cryogenic minimum quantity lubrication energy field-assisted milling

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Nomenclature

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 field-assisted 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
Variables
A	Vibration amplitude
dL	Heat source size
f	Vibration frequency
fz	Feed per tooth
Nz	Number of tips
Pci	Coordinate tool point
Pli	Initial coordinate point
PL	Laser power
PLi	End coordinate point
r	Radius of the cutting tool
rc	Sum of the radius of the cutting tool
R	Expected fillet radius
Sa	Average roughness
Sq	Surface root mean square roughness
t	Cutting time
vc	Cutting speed
vf	Feed speed
VL	Laser scanning speed
x, y, z	Tip displacements
xcl	Distance between the tool center and the laser heat source center
xL	Distance between spot and tool
ωr	Angular velocity of the spindle
αi	Tool radius angle
αp	Axial cutting depth
αe	Radial cut width
β	Tool rotation angle
θ	Initial phase of the vibration signal
∆xi	Distance between the initial coordinate point of the heat source and the end coordinate point

Acknowledgements

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.

Conflict of Interest

The authors declare that they have no conflict of interest.

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