Structure Improvement and Optimization of Gantry Milling System for Complex Boring and Milling Machining Center

To enhance the efficiency and machining precision of the TX1600G complex boring and milling machining center,a study was conducted on the structure of its gantry milling system.This study aimed to mitigate the influence of factors such as structural quality,natural frequency,and stiffness.The approach employed for this investigation involved mechanism topology optimization.To initiate this process,a finite element model of the gantry milling system structure was established.Subsequently,an objective function,comprising strain energy and modal eigenvalues,was synthesized.This objective function was optimized through multi-objective topology optimization,taking into account certain mass fraction constraints and considering various factors,including processing technology.The ultimate goal of this optimization was to create a gantry milling structure that exhibited high levels of dynamic and static stiffness,a superior natural frequency,and reduced mass.To validate the effectiveness of these topology optimization results,a comparison was made between the new and previous structures.The findings of this study serve as a valuable reference for optimizing the structure of other components within the machining center.

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.

Dynamic synchronous motion accuracy measurement and estimation for a five-axis mirror milling system

A mirror milling system(MMS)comprises two face-to-face five-axis machine tools,one for the cutting spindle and the other for the support tool.Since it is essential to maintain the cutter and support coaxial during the cutting process,synchronous motion accuracy is the key index of the MMS.This paper proposed a novel method for measuring and estimating the synchronous motion accuracy of the dual five-axis machine tools.The method simultaneously detects errors in the tool center point(TCP)and tool axis direction(TAD)during synchronous motion.To implement the suggested method,a measurement device,with five high-precision displacement sensors was developed.A kinematic model was then developed to estimate the synchronous motion accuracy from the displacement sensor output.The screw theory was used to obtain the analytical expression of the inverse kinematic model,and the synchronous motion error was compensated and adjusted based on the inverse kinematic model of the dual five-axis machine tools.TCP and TAD quasi-static errors,such as geometric and backlash errors,were first compensated.By adjusting the servo parameters,the dynamic TCP and TAD errors,such as gain mismatch and reversal spike,were also reduced.The proposed method and device were tested in a large MMS,and the measured quasi-static and dynamic errors were all reduced when the compensation and adjustment method was used.Monte Carlo simulations were also used to estimate the uncertainty of the proposed scheme.

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.

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.

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.

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.

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.

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.

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.

A multi-order method for predicting stability of a multi-delay milling system considering helix angle and run-out effects

In this paper, a multi-delay milling system considering helix angle and run-out effects is firstly established. An exponential cutting force model is used to model the interaction between a work-piece and a cutting tool, and a new approach is presented for accurately calibrating exponential cutting force coefficients and cutter run-out parameters. Furthermore, based on an implicit multi-step Adams formula and an improved precise time-integration algorithm, a novel stability prediction method is proposed to predict the stability of the system. The involved time delay term and periodic coefficient term are integrated as a comprehensive state term in the integral response which is approximated by the Adams formula. Then, a Floquet transition matrix with an arbitraryorder form is constructed by using a series of matrix multiplication, and the stability of the system is determined by the Floquet theory. Compared to classical semi-discretization methods and fulldiscretization methods, the developed method shows a good performance in convergence, efficiency,accuracy, and multi-order complexity. A series of cutting tests is further carried out to validate the practicability and effectiveness of the proposed method. The results show that the calibration process needs a time of less than 5 min, and the stability prediction method is effective.

WORKPIECE LOCATING AND POST PROCESSING SYSTEMS ON 6-DOF CNC MILLING MACHINE

A conventional non-computerized numerical control （CNC） machine is updated by mounting a six degree-of-free （DOF） parallel mechanism on it, thus obtaining a new CNC one. The structure of this CNC milling machine is introduced, and the workpiece locating system and the post processing system of the cutter location （CL） data file are analyzed. The new machine has advantages of low costs, simple structure, good rigidity, and high precision. It is easy to be transformed and used to process the workpiece with a complex surface.

Milling Fault Detection Method Based on Fault Tree Analysis and Hierarchical Belief Rule Base

Expert knowledge is the key to modeling milling fault detection systems based on the belief rule base.The construction of an initial expert knowledge base seriously affects the accuracy and interpretability of the milling fault detection model.However,due to the complexity of the milling system structure and the uncertainty of the milling failure index,it is often impossible to construct model expert knowledge effectively.Therefore,a milling system fault detection method based on fault tree analysis and hierarchical BRB(FTBRB)is proposed.Firstly,the proposed method uses a fault tree and hierarchical BRB modeling.Through fault tree analysis(FTA),the logical correspondence between FTA and BRB is sorted out.This can effectively embed the FTA mechanism into the BRB expert knowledge base.The hierarchical BRB model is used to solve the problem of excessive indexes and avoid combinatorial explosion.Secondly,evidence reasoning(ER)is used to ensure the transparency of the model reasoning process.Thirdly,the projection covariance matrix adaptation evolutionary strategies(P-CMA-ES)is used to optimize the model.Finally,this paper verifies the validity model and the method’s feasibility techniques for milling data sets.

Design and Implementation of a System for Laser Assisted Milling of Advanced Materials

Laser assisted machining is an effective method to machine advanced materials with the added benefits of longer tool life and increased material removal rates. While extensive studies have investigated the machining properties for laser assisted milling（LAML）, few attempts have been made to extend LAML to machining parts with complex geometric features. A methodology for continuous path machining for LAML is developed by integration of a rotary and movable table into an ordinary milling machine with a laser beam system. The machining strategy and processing path are investigated to determine alignment of the machining path with the laser spot. In order to keep the material removal temperatures above the softening temperature of silicon nitride, the transformation is coordinated and the temperature interpolated, establishing a transient thermal model. The temperatures of the laser center and cutting zone are also carefully controlled to achieve optimal machining results and avoid thermal damage. These experiments indicate that the system results in no surface damage as well as good surface roughness, validating the application of this machining strategy and thermal model in the development of a new LAML system for continuous path processing of silicon nitride. The proposed approach can be easily applied in LAML system to achieve continuous processing and improve efficiency in laser assisted machining.

Tribological Performance of Different Concentrations of Al_(2)O_(3)Nanofluids on Minimum Quantity Lubrication Milling

Nanofluid minimum quantity lubrication(NMQL)is a green processing technology.Cottonseed oil is suitable as base oil because of excellent lubrication performance,low freezing temperature,and high yield.Al_(2)O_(3)nanoparticles improve not only the heat transfer capacity but also the lubrication performance.The physical and chemical proper-ties of nanofluid change when Al_(2)O_(3)nanoparticles are added.However,the effects of the concentration of nanofluid on lubrication performance remain unknown.Furthermore,the mechanisms of interaction between Al_(2)O_(3)nanoparti-cles and cottonseed oil are unclear.In this research,nanofluid is prepared by adding different mass concentrations of Al_(2)O_(3)nanoparticles(0,0.2%,0.5%,1%,1.5%,and 2%wt)to cottonseed oil during minimum quantity lubrication(MQL)milling 45 steel.The tribological properties of nanofluid with different concentrations at the tool/workpiece interface are studied through macro-evaluation parameters(milling force,specific energy)and micro-evaluation parameters(surface roughness,micro morphology,contact angle).The result show that the specific energy is at the minimum(114 J/mm^(3)),and the roughness value is the lowest(1.63μm)when the concentration is 0.5 wt%.The surfaces of the chip and workpiece are the smoothest,and the contact angle is the lowest,indicating that the tribological proper-ties are the best under 0.5 wt%.This research investigates the intercoupling mechanisms of Al_(2)O_(3)nanoparticles and cottonseed base oil,and acquires the optimal Al_(2)O_(3)nanofluid concentration to receive satisfactory tribological properties.

Experimental Study on Titanium Alloy Cutting Property and Wear Mechanism with Circular-arc Milling Cutters

Titanium alloy has been applied in the field of aerospace manufacturing for its high specific strength and hardness.Nonetheless,these properties also cause general problems in the machining,such as processing inefficiency,serious wear,poor workpiece face quality,etc.Aiming at the above problems,this paper carried out a comparative experimental study on titanium alloy milling based on the CAMCand BEMC.The variation law of cutting force and wear morphology of the two tools were obtained,and the wear mechanism and the effect of wear on machining quality were analyzed.The conclusion is that in contrast with BEMC,under the action of cutting thickness thinning mechanism,the force of CAMC was less,and its fluctuation was more stable.The flank wear was uniform and near the cutting edge,and the wear rate was slower.In the early period,the wear mechanism of CAMC was mainly adhesion.Gradually,oxidative wear also occurred with milling.Furthermore,the surface residual height of CAMC was lower.There is no obvious peak and trough accompanied by fewer surface defects.

Effect of ball milling time on the microstructure and compressive properties of the Fe–Mn–Al porous steel

In the present work,Fe–Mn–Al–C powder mixtures were manufactured by elemental powders with different ball milling time,and the porous high-Mn and high-Al steel was fabricated by powder sintering.The results indicated that the powder size significantly decreased,and the morphology of the Fe powder tended to be increasingly flat as the milling time increased.However,the prolonged milling duration had limited impact on the phase transition of the powder mixture.The main phases of all the samples sintered at 640℃ were α-Fe,α-Mn and Al,and a small amount of Fe2Al5 and Al8Mn5.When the sintering temperature increased to 1200℃,the phase composition was mainly comprised of γ-Fe and α-Fe.The weight loss fraction of the sintered sample decreased with milling time,i.e.,8.3wt% after 20 h milling compared to15.3wt% for 10 h.The Mn depletion region(MDR) for the 10,15,and 20 h milled samples was about 780,600,and 370 μm,respectively.The total porosity of samples sintered at 640℃ decreased from ~46.6vol% for the 10 h milled powder to ~44.2vol% for 20 h milled powder.After sintering at 1200℃,the total porosity of sintered samples prepared by 10 and 20 h milled powder was ~58.3vol% and ~51.3vol%,respectively.The compressive strength and ductility of the 1200℃ sintered porous steel increased as the milling time increased.

Health Monitoring of Milling Tool Inserts Using CNN Architectures Trained by Vibration Spectrograms

In-process damage to a cutting tool degrades the surface􀀀nish of the job shaped by machining and causes a signi􀀀cant􀀀nancial loss.This stimulates the need for Tool Condition Monitoring(TCM)to assist detection of failure before it extends to the worse phase.Machine Learning(ML)based TCM has been extensively explored in the last decade.However,most of the research is now directed toward Deep Learning(DL).The“Deep”formulation,hierarchical compositionality,distributed representation and end-to-end learning of Neural Nets need to be explored to create a generalized TCM framework to perform eciently in a high-noise environment of cross-domain machining.With this motivation,the design of dierent CNN(Convolutional Neural Network)architectures such as AlexNet,ResNet-50,LeNet-5,and VGG-16 is presented in this paper.Real-time spindle vibrations corresponding to healthy and various faulty con􀀀gurations of milling cutter were acquired.This data was transformed into the time-frequency domain and further processed by proposed architectures in graphical form,i.e.,spectrogram.The model is trained,tested,and validated considering dierent datasets and showcased promising results.

Study of Reactions Induced by Mechanical Milling in ZnO-α-Fe_2O_3 System

Spinel ferrite ZnFe 2O 4 powders were synthesized directly from ZnO and α Fe 2O 3 mixtures by high energy mechanical milling. X ray diffraction (XRD) and high resolution transmission electron microscopy (HRTEM) were used to investigate the chemical reaction processing at different milling time. It has been found that the solid reactions between metal oxides are characterized by stages. Once the solid chemical synthesized reaction is initialized, it proceeds quickly and can be completed in very short time. Grain sizes of ZnFe 2O 4 are less than 10 nm.