Micro-EDM Milling of Complex 3D Structure with Fix-Length Compensation Method

A human face with complex 3D structure is machined with a modified fix-length compensation method in this paper.The fast development of MEMS (Micro Electromechanical Systems) has strongly enhanced the application of new harder work materials.As a low cost,flexible,good repeatable machining process with negligible process forces,micro-EDM milling is well suited for freeform metallic micro structures.A major problem in micro-EDM milling of complex 3D structure is the electrode wear.A new CAM system based on the UG software platform is developed in order to get good accuracy and higher efficiency.A correction coefficient is introduced and deduced for the modified fix-length compensation method.Using this method a human face with complex 3D stricter is machined successfully by micro-EDM milling.

Effects of Milling Methods on Rice Flour Properties and Rice Product Quality:A Review

High-quality rice flour is the foundation for the production of various rice-based products.Milling is an essential step in obtaining rice flour,during which significant changes occur in the physicochemical and quality characteristics of the flour.Although rice flour obtained through mainstream wet milling methods exhibits superior quality,low production efficiency and wastewater discharge limit the development of the industry.Dry milling,on the other hand,conserves water resources,but adversely affects flour performance due to excessive heat generation.As an emerging powder-making technique,semi-dry milling offers a promising solution by enhancing flour quality and reducing environmental impact.This is achieved by minimizing soaking time through hot air treatment while reducing mechanical energy consumption to reach saturated water absorption levels.However,continuous production remains a challenge.This comprehensive review summarizes the effects of various milling technologies on rice flour properties and product qualities.It also discusses key control indicators and technical considerations for rice flour processing equipment and processes.

Balanced Fracturing and Cold-welding of Magnesium during Ball Milling Assisted by Carbon Coating:Experimental and Molecular Dynamic Simulation

The lignite-derived carbon from self-protection pyrolysis was employed to balance the fracturing and cold-welding of magnesium during ball milling.Particle size analysis indicates that the introduction of lignite-derived carbon can effectively reduce the particle size of Mg while the introduction of graphite does no help.Besides,the effect of lignite-derived carbon on crystallite size reduction of Mg is also better than graphite.A moderate cold-welding phenomenon was observed after ball-milling Mg with the lignite-derived carbon,suggesting less Mg is wasted on the milling vials and balls.Molecular dynamic simulations reveal that the balanced fracturing and cold-welding of magnesium during ball milling is mainly attributed to the special structure of the lignite-derived carbon:graphitized short-range ordered stacking function as dry lubricant and irregular shape/sharp edge function as milling aid.The preliminary findings in current study are expected to offer implications for designing efficient Mg-based hydrogen storage materials.

Milling degree affects the fermentation properties of rice:perspectives from the composition of nutrients and gut microbiota via in vitro fermentation

Fermentation substrates of rice with different milling degrees(MDs) were prepared and fermented with human feces to compare their fermentation properties and effects on gut microbiota.MD 0s,MD 5s and MD 60s represented brown rice,moderately-milled rice and white rice,respectively.After in vitro fermentation,the MD 5s group showed higher starch utilization,compared with the MD 0s and 60s groups evaluated by Fourier transform infrared spectrometer,and confocal laser scanning microscope.Effects of fermentation substrates of rice with different MDs on gut microbiota were evaluated by 16S rDNA sequencing.All the sample groups reduced the pH and produced short-chain fatty acids(SCFAs) and branched-chain fatty acids.The MD 5s group exhibited higher α-diversity than the MD 0s and 60s groups.Abundances of Phascolarctobacterium,Blautia and norank_f_Ruminococcaceae were higher in the MD 0s and 5s groups,compared with the MD 60s group.These bacteria were also positively correlated with the SCFAs production via Spearman correlation analysis.In vitro culture assay revealed that fermentation substrates of MD 0s and 5s promoted the growth of two probiotics(Akkermansia muciniphila and Bifidobacterium adolescentis).Our results showed that moderate milling might be an appropriate way to produce rice products with richer nutrients and better fermentation properties.

Improving hydrogen storage thermodynamics and kinetics of Ce-Mg-Ni-based alloy by mechanical milling with TiF_(3)

Mg-based hydrides are too stable and the kinetics of hydrogen absorption and desorption is not satisfactory.An efficient way to improve these shortcomings is to employ reactive ball milling to synthesize the nanocomposite materials of Mg and additives.In this experiment,TiF_(3)was selected as an additive,and the mechanical milling method was employed to prepare the experimental alloys.The alloys used in this experiment were the as-cast Ce_(5)Mg_(85)Ni_(10),as-milled Ce_(5)Mg_(85)Ni_(10)and Ce_(5)Mg_(85)Ni_(10)+3 wt.%TiF3.The phase transformation,structural evolution,isothermal and non-isothermal hydrogenation and dehydrogenation performances of the alloys were inspected by XRD,SEM,TEM,Sievert apparatus,DSC and TGA.It revealed that nanocrystalline appeared in the as-milled samples.Compared with the as-cast alloy,ball milling made the particle dimension and grain size decrease dramatically and the defect density increase significantly.The addition of TiF_(3)made the surface of ball milling alloy particles markedly coarser and more irregular.Ball milling and adding TiF_(3)distinctly improved the activation and kinetics of the alloys.Moreover,ball milling along with TiF_(3)can decrease the onset dehydrogenation temperature of Mg-based hydrides and slightly ameliorate their thermodynamics.

Distribution of antioxidants and phenolic compounds in flour milling fractions from hard red winter wheat

Mature wheat kernels contain three main parts:endosperm,bran,and germ.Flour milling results in multiple streams that are chemically different;however,the distribution of antioxidants and phenolic compounds has not been well documented in terms of conventional milling by-product streams.In this study,multiple analytical methods were used to investigate antioxidant activity and phenolic compound compositions of hard red winter wheat(whole ground wheat),the parts of a wheat kernel(bran,flour,germ),and wheat by-product streams(mill feed,red dog,shorts)for the first time.For each mill stream,phenolic compounds(total,flavonoid,and anthocyanin contents)were determined and antioxidant activities were evaluated with 1,1-diphenyl-2-picrylhydrazyl(DPPH)radical-scavenging activity,ferric reducing/antioxidant power(FRAP),and total antioxidant capacity assays.Significant differences(P<0.05)were observed in phenolic concentrations among fractions of bran,flour,and germ milled from the same kernels and noted that germ accounts for the majority of antioxidant properties,whereas bran contains a substantial portion of phenolic compounds and anthocyanins.Mill feed was high in phenolic content(5.29 mg FAE/g),total antioxidant capacity(866 mg/g),and antioxidant activity(up to 75% DPPH inhibition and 20.26μmol FeSO_(4)/g).The comprehensive information on distribution of antioxidants and phenolic compounds provides insights for future human consumption of commonly produced co-products from flour milling,and for selecting and using different milling fractions to make foods with improved nutritional properties.

Improved length of calcium sulfate crystal seeds and whiskers via ball milling and hydration treatment

Elucidating the effect of growth periods on the quality of calcium sulfate whiskers(CSWs)prepared from calcium sulfate dihydrate(DH)is imperative.Herein,crystal seeds and whiskers were prepared from DH in a water–glycerol system.Longer whiskers were obtained from crystal seeds prepared via hydration of DH for 30 s than via ball milling for 5 min followed by hydration for 20 s.The attachment of cetyltrimethyl ammonium bromide and glycerol additives to the whisker tops promoted whisker growth.The whisker sponges exhibited good thermal barrier properties and compression cycle stability.

Theoretical Modeling and Surface Roughness Prediction of Microtextured Surfaces in Ultrasonic Vibration-Assisted Milling

Textured surfaces with certain micro/nano structures have been proven to possess some advanced functions,such as reducing friction,improving wear and increasing wettability.Accurate prediction of micro/nano surface textures is of great significance for the design,fabrication and application of functional textured surfaces.In this paper,based on the kinematic analysis of cutter teeth,the discretization of ultrasonic machining process,transformation method of coordinate systems and the cubic spline data interpolation,an integrated theoretical model was established to characterize the distribution and geometric features of micro textures on the surfaces machined by different types of ultrasonic vibration-assisted milling(UVAM).Based on the theoretical model,the effect of key process parameters(vibration directions,vibration dimensions,cutting parameters and vibration parameters)on tool trajectories and microtextured surface morphology in UVAM is investigated.Besides,the effect of phase difference on the elliptical shape in 2D/3D ultrasonic elliptical vibration-assisted milling(UEVAM)was analyzed.Compared to conventional numerical models,the method of the cubic spline data interpolation is applied to the simulation of microtextured surface morphology in UVAM,which is more suitable for characterizing the morphological features of microtextured surfaces than traditional methods due to the presence of numerous micro textures.The prediction of surface roughness indicates that the magnitude of ultrasonic amplitude in z-direction should be strictly limited in 1D rotary UVAM,2D and 3D UEVAM due to the unfavorable effect of axial ultrasonic vibration on the surface quality.This study can provide theoretical guidance for the design and fabrication of microtextured surfaces in UVAM.

An electromagnetic semi-active dynamic vibration absorber for thin-walled workpiece vibration suppression in mirror milling

As critical components of aircraft skins and rocket fuel storage tank shells,large thin-walled workpieces are susceptible to vibration and deformation during machining due to their weak local stiffness.To address these challenges,we propose a novel tunable electromagnetic semi-active dynamic vibration absorber(ESADVA),which integrates with a magnetic suction follower to form a followed ESADVA(follow-ESADVA)for mirror milling.This system combines a tunable magnet oscillator with a follower,enabling real-time vibration absorption and condition feedback throughout the milling process.Additionally,the device supports self-sensing and frequency adjustment by providing feedback to a linear actuator,which alters the distance between magnets.This resolves the traditional issue of being unable to directly monitor vibration at the machining point due to space constraints and tool interference.The frequency shift characteristics and vibration absorption performance are comprehensively investigated.Theoretical and experimental results demonstrate that the prototyped follow-ESADVA achieves frequency synchronization with the milling tool,resulting in a vibration suppression rate of approximately 47.57%.Moreover,the roughness of the machined surface decreases by18.95%,significantly enhancing the surface quality.The results of this work pave the way for higher-quality machined surfaces and a more stable mirror milling process.

Solution and Analysis of Chatter Stability for End Milling in the Time-domain

In this paper, the instantaneous undeformed chip thickness is modeled to include the dynamic modulation caused by the tool vibration while the dynamic regenerative effects are taken into account. The numerical method is used to solve the differential equations goveming the dynamics of the milling system. Several chatter detection criteria are applied synthetically to the simulated signals and the stability diagram is obtained in time-domain. The simulation results in time-domain show a good agreement with the analytical prediction, which is validated by the cutting experiments. By simulating the chatter stability lobes in the time-domain and analyzing the influences of different spindle speeds on the vibration amplitudes of the tool under a Fixed chip-load condition, conclusions could be drawn as follows： In rough milling, higher machining efficiency can be achieved by selecting a spindle speed corresponding to the axial depth of cut in accordance with the simulated chatter stability lobes, and in Fmish milling, lower surface roughness can be achieved by selecting a spindle speed well beyond the resonant frequency of machining system.

CUTTING TEMPERATURE MEASUREMENT IN HIGH-SPEED END MILLING

A computer aided measurement system is used to measure the cutting temperature directly in high-speed machining by natural thermocouples and standard thermocouples. In this system the tool/workpiece interface temperature is measured by the tool/workpiece natural thermocouple, while the temperature distribution on the workpiece surface and that of interior are measured by some standard thermocouples prearranged at proper positions. The system can be used to measure cutting temperature in the machining with the rotary cutting tools, such as vertical drill and end milling cutter. It is practically used for the research on high-speed milling with hardened steel.

Influence of high-speed milling parameter on 3D surface topography and fatigue behavior of TB6 titanium alloy

High-speed milling of titanium alloys is widely used in aviation and aerospace industries for its high efficiency and good quality.In order to optimize the machining parameters in high-speed milling TB6 titanium alloy,experiments of high-speed milling and fatigue were conducted to investigate the effect of parameters on 3D surface topography and fatigue life.Based on the fatigue fracture,the effect mechanism of surface topography on the fatigue crack initiation was proposed.The experiment results show that when the milling speed ranged from 100 m/min to 140 m/min,and the feed per tooth ranged from 0.02 mm/z to 0.06 mm/z,the obtained surface roughness were within the limit（0.8 μm）.Fatigue life decreased sharply with the increase of surface equivalent stress concentration factor.The average error of fatigue life between the established model and the experimental results was 6.25%.The fatigue cracks nucleated at the intersection edge of machined surface.

ANALYSIS ON SURFACE INTEGRITY DURING HIGH SPEED MILLING FOR NEW DAMAGE-TOLERANT TITANIUM ALLOY

Surface integrity of a new damage-tolerant titanium alloy （TC21）, including surface roughness, microhardness and metallurgical structure is investigated when normal and high speed milling are used at different tool wear status. Results show that good surface integrity of TC21 can be obtained in high speed milling. In addition, even in acutely worn stages, there is no so-called serious hardening layer （or white layer） according to the studies on microhardness and metallurgical structure.

Effects of high-energy ball milling oxide-doped and varistor ceramic powder on ZnO varistor

ZnO varistor ceramics doped with Bi2O3, Sb2O3, CO2O3, Cr2O3, and MnO2 were prepared separately by two high-energy ball milling processes： oxide-doped and varistor ceramic powder. A comparison in the electrical and microstructural properties of the samples obtained by both methods was made. The best results on these characteristics were achieved through the high-energy ball milling varistor ceramic powder route, obtaining a nonlinear coefficient of 57 and a breakdown field of 617 V/mm at a sintering temperature of 1000 ℃ for 3 h. The samples synthesized by this technique show not only high density value, 95% of the theoretical density, but also a homogeneous microstructure, which compete with those obtained by the high-energy ball milling oxide-doped powder route. With the advantage that the high-energy ball milling varistor ceramic powder route can refine grain, increase the driving force of sintering, accelerate the sintering process, and reduce the sintering temperature.

NOVEL METHOD FOR DYNAMIC OPTIMIZATION OF STABILITY IN HIGH-SPEED MILLING SYSTEM

Considering the self-excited and forced vibrations in high-speed milling processes, a novel method for dynamic optimization of system stability is used to determine the cutting parameters and structural parameters by increasing the chatter free material removal rate （CF-MRR） and surface finish. The method is hased on the theory of the chatter stability and the semi-bandwidth of the resonant region. The objective function of the method is material removal rate（MRR）,the constraints are chatter stability and surface finish, and the optimizing variables are cutting and structural parameters. The optimization procedure is stated. The method is applied to a milling system and CF-MRR is increased 18.86%. It is shown that the influences of the chatter stability and the resonance are simultaneously considered in the dynamic optimization of the milling system for increasing CF-MRR and the surface finish.

Effect of milling time on carbothermic reduction of ilmenite

A systematic investigation on the effect of milling time on carbothermic reduction of ilmenite was carried out by a combination of thermal analysis, X-ray diffraction（XRD）, scanning electron microscopy（SEM） and particle size analysis. It was shown that the graphite crystalline structure was easily destroyed along the（002） crystal plane during milling process. The particle size of ilmenite/graphite mixture was largely decreased and a fully mixed composite structure was obtained after milling for 4 h at high milling intensity. Milling exerts positive effect on the decreasing temperatures of ilmenite reduction and gradual deoxidizing of titanium oxides was completed.

TOOL WEAR PATTERNS AND MECHANISMS OF SOLID CEMENTED CARBIDE IN HIGH-SPEED MILLING OF ALUMINUM ALLOY

The wear patterns and wear mechanisms of solid cemented carbide are analyzed in high-speed milling of aluminum alloy. Results show that the dominant wear patterns are coating damage, crater wear, micro-chipping, breakage, and so on. The main wear mechanisms are adhesion, diffusion and fatigue. Compared with conventional speed machining, the effect and impact of thermal-dynamical coupling field play an important role in the cutting tool wear in high-speed milling of aluminum alloy.

MILLER WEAR IN MILLING Ti ALLOY WITH NITROGEN GAS MEDIA

Milling Ti alloy is a very difficult technology. The primary problem is that the miller wear is very rapid and makes the miller break or rapture. Although cutting fluid is mainly used to reduce friction and temperature in cutting area to enhance tool life, it is the largest source of environmental pollution. To develop a technology for the clean and efficient milling Ti alloys, nitrogen gas is used as a cutting media in this paper. Based on lots of experiments and researches, the tool life and wear mechanism of high speed steel miller is analyzed. A conclusion is drawn that, milling with nitrogen gas media yields much longer tool life than dry milling. Tool life equations (Taylor′s equations) are derived for both milling types.

NC MILLING OPERATION SIMULATION

Due to the unproductive and time consuming of the test cut, it is important to recognize all the possible errors before starting the process. This paper introduces a simulation program which can be used in an NC vertical milling machine. A unique method is used for simulating the cutting process and displaying the three dimensional images. This method not only simplifies greatly the treatment of the hidden line but also creates a “photograph effect” image. The program is written in Visual B.

INFLUENCE OF TOOL HELIX ANGLE ON STABILITY IN HIGH-SPEED MILLING PROCESS

An integrated dynamic model considering the influence of the helix angle is developed through dividing the cutting process into three cutting processes： uninterrupted, entry, and exit cutting processes. The semi-discretized technique is used to approximate the finite dimensional Floquet transition matrix of the dynamic control equation to determine the stability of milling process. The stability charts for helix mills are obtained. Results show that the helix angle plays an important role in the stability of milling process. The stability regions with helix angle become larger than those without helix angle. Some ＂islands＂ are presented in the stability charts, and ＂island＂ locations are determined by the relation between the axial depth of cut and the helix pitch. The ＂islands＂ are connected by the ＂bridge＂ by the effects of entry and exit cutting processes. The theoretical results are validated by milling experiments.