Force model in electrostatic atomization minimum quantity lubrication milling GH4169 and performance evaluation

Abstract

The nickel-based high-temperature alloy GH4169 is the material of choice for manufacturing critical components in aeroengines, and electrostatic atomization minimum quantity lubrication (EMQL) milling represents a fundamental machining process for GH4169. However, the effects of electric field parameters, jet parameters, nozzle position, and milling parameters on milling performance remain unclear, which constrains the broad application of EMQL in aerospace manufacturing. This study evaluated the milling performance of EMQL on nickel-based alloys using soybean oil as the lubrication medium. Results revealed that compared with conventional pneumatic atomization MQL milling, EMQL reduced the milling force by 15.2%–15.9%, lowered the surface roughness by 30.9%–54.2%, decreased the average roughness spacing by 47.4%–58.3%, and decreased the coefficient of friction and the specific energy of cutting by 55% and 19.6%, respectively. Subsequent optimization experiments using orthogonal arrays demonstrated that air pressure most significantly affected the milling force and specific energy of cutting, with a contribution rate of 22%, whereas voltage had the greatest effect on workpiece surface roughness, contributing 36.71%. Considering the workpiece surface morphology and the potential impact of droplet drift on environmental and health safety, the optimal parameter combination identified were a flow rate of 80 mL/h, an air pressure of 0.1 MPa, a voltage of 30 kV, a nozzle incidence angle of 35°, an elevation angle of 30°, and a target distance of 40 mm. This research aimed to provide technical insights for improving the surface integrity of aerospace materials that are difficult to machine during cutting operations.

Graphical abstract

Keywords

electrostatic atomization / MQL / nickel-based alloys / milling force / surface roughness / force model

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Acknowledgements

This study was financially supported by the National Natural Science Foundation of China (Grant No. 52205481), the Support Plan for Outstanding Youth Innovation Team in Universities of Shandong Province, China (Grant No. 2023KJ114), and the Qingdao Science and Technology Planning Park Cultivation Plan, China (Grant No. 23-1-5-yqpy-17-qy).

Conflict of Interest

Changhe LI is a member of the Editorial Board of Frontiers of Mechanical Engineering, who was excluded from the peer review process and all editorial decisions related to the acceptance and publication of this article. Peer review was handled independently by the other editors to minimize bias.

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