Aluminum alloy is the main structural material of aircraft,launch vehicle,spaceship,and space station and is processed by milling.However,tool wear and vibration are the bottlenecks in the milling process of aviation ...Aluminum alloy is the main structural material of aircraft,launch vehicle,spaceship,and space station and is processed by milling.However,tool wear and vibration are the bottlenecks in the milling process of aviation aluminum alloy.The machining accuracy and surface quality of aluminum alloy milling depend on the cutting parameters,material mechanical properties,machine tools,and other parameters.In particular,milling force is the crucial factor to determine material removal and workpiece surface integrity.However,establishing the prediction model of milling force is important and difficult because milling force is the result of multiparameter coupling of process system.The research progress of cutting force model is reviewed from three modeling methods:empirical model,finite element simulation,and instantaneous milling force model.The problems of cutting force modeling are also determined.In view of these problems,the future work direction is proposed in the following four aspects:(1)high-speed milling is adopted for the thin-walled structure of large aviation with large cutting depth,which easily produces high residual stress.The residual stress should be analyzed under this particular condition.(2)Multiple factors(e.g.,eccentric swing milling parameters,lubrication conditions,tools,tool and workpiece deformation,and size effect)should be considered comprehensively when modeling instantaneous milling forces,especially for micro milling and complex surface machining.(3)The database of milling force model,including the corresponding workpiece materials,working condition,cutting tools(geometric figures and coatings),and other parameters,should be established.(4)The effect of chatter on the prediction accuracy of milling force cannot be ignored in thin-walled workpiece milling.(5)The cutting force of aviation aluminum alloy milling under the condition of minimum quantity lubrication(mql)and nanofluid mql should be predicted.展开更多
By adopting an equivalent geometry model of machining process and considering thermo-plastic properties of the work material, a finite element method(FEM) to study oblique milling process of aluminum alloy with a doub...By adopting an equivalent geometry model of machining process and considering thermo-plastic properties of the work material, a finite element method(FEM) to study oblique milling process of aluminum alloy with a double-edge tool was presented. In the FEM, shear flow stress was determined by material test. Re-meshing technology was used to represent chip separation process. Comparing the predicted cutting forces with the measured forces shows the 3D FEM is reasonable. Using this FEM, chip forming process and temperature distribution were predicted. Chips obtained by the 3D FEM are in spiral shape and are similar to the experimental ones. Distribution and change trend of temperature in the tool and chip indicate that contact length between tool rake face and chip is extending as tool moving forward. These results confirm the capability of FEM simulation in predicting chip flow and selecting optimal tool.展开更多
Nano-sized MoSi2 powder was produced successfully from commercially available MoSi2 by a mechanical milling process carried out for 100 h, and mechanical alloying was employed to synthesize AA 2024-MoSi2 nanocomposite...Nano-sized MoSi2 powder was produced successfully from commercially available MoSi2 by a mechanical milling process carried out for 100 h, and mechanical alloying was employed to synthesize AA 2024-MoSi2 nanocomposites, The effects of MoSi2 reinforcement and mechanical milling on the structure, morphology, and iron contamination of the produced materials were investigated using X-ray diffraction, scanning electron microscopy, and atomic absorption spectrometry. It is revealed that the morphology of the aluminum alloy changes continuously during milling from spherical to plate-like, irregular, and finally equiaxed. The presence of MoSi2 reinforcement accelerates the milling process and results in a smaller average particle size. The Williamson-Hall method determined that the crystallite size of the aluminum alloy in the composite powder is smaller than that of the unreinforced alloy at the same milling time and this size reaches 45 nm after 16 h milling time. The Fe contamination content is higher for the nanocomposite in comparison with the unreinforced alloy because of the wearing role of MoSi2 hard particles.展开更多
Fatigue failure is one of the main failure forms of Al-Si-Cu-Mg aluminum alloys.To feature their mechanical aspect of fatigue behavior,the low-cycle fatigue behavior of permanent mold cast and die-cast Al-Si-Cu-Mg all...Fatigue failure is one of the main failure forms of Al-Si-Cu-Mg aluminum alloys.To feature their mechanical aspect of fatigue behavior,the low-cycle fatigue behavior of permanent mold cast and die-cast Al-Si-Cu-Mg alloys at room temperature was investigated.The experimental results show that both permanent mold cast and die-cast Al-Si-Cu-Mg alloys mainly exhibit cyclic strain hardening.At the same total strain amplitude,the die-cast Al-Si-Cu-Mg alloy shows higher cyclic deformation resistance and longer fatigue life than does the permanent mold cast Al-Si-Cu-Mg alloy.The relationship between both elastic and plastic strain amplitudes with reversals to failure shows a monotonic linear behavior,and can be described by the Basquin and Coffin-Manson equations,respectively.展开更多
This article mainly discussed bulk material prepared by powder metallurgy,and the commercial 2024 aluminum alloy powder and FeNiCrCoAl 3 high entropy alloy powder( both produced by argon gas atomization process) were ...This article mainly discussed bulk material prepared by powder metallurgy,and the commercial 2024 aluminum alloy powder and FeNiCrCoAl 3 high entropy alloy powder( both produced by argon gas atomization process) were ball-milled for different hours. The prepared powder was consolidated by hot extrusion method. The microstructures of the milled powder and bulk alloy were examined by X- Ray Diffraction( XRD), Scanning Electron Microscopy( SEM) and Transmission Electron Microscopy( TEM). The thermal stability was tested by differential scanning calorimetry( DSC). Mechanical properties of the extruded alloy were examined by Vickers hardness tester and mechanical testing machine. The results show that after milling,the mixed particle sizes and microstructures of the alloy powder change obviously. The compressive strength of the extruded alloy has reached 580 MPa under certain conditions of milling time and composition.展开更多
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 m...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.展开更多
Metal matrix composites （MMCs） with high specific stiffness, high strength, improved wear resistance, and thermal properties are being increasingly used in advanced structural, aerospace, automotive, electronics, an...Metal matrix composites （MMCs） with high specific stiffness, high strength, improved wear resistance, and thermal properties are being increasingly used in advanced structural, aerospace, automotive, electronics, and wear applications. Aluminum alloy-silicon carbide composites were developed using a new combination of the vortex method and the pressure die-casting technique in the present work. Machining studies were conducted on the aluminum alloy-silicon carbide （SiC） composite work pieces using high speed steel （HSS） end-mill tools in a milling machine at different speeds and feeds. The quantitative studies on the machined work piece show that the surface finish is better for higher speeds and lower feeds. The surface roughness of the plain aluminum alloy is better than that of the aluminum alloy-silicon carbide composites. The studies on tool wear show that flank wear increases with speed and feed. The end-mill tool wear is higher on machining the aluminum alloy-silicon carbide composites than on machining the plain aluminum alloy.展开更多
This study investigated the effects of carbon nanotube （CNT） concentration on the micro-morphologies and laser absorption proper- ties of CNT/AlSi10Mg composite powders produced by high-energy ball milling. A scanni...This study investigated the effects of carbon nanotube （CNT） concentration on the micro-morphologies and laser absorption proper- ties of CNT/AlSi10Mg composite powders produced by high-energy ball milling. A scanning electron microscope, X-ray diffractometer, laser particle size analyzer, high-temperature synchronous thermal analyzer, and UV/VIS/NIR spectrophotometer were used for the analysis of micro- graphs, phases, granulometric parameters, thermal properties, and laser absorption properties of the composite powders, respectively. The results showed that the powders gradually changed from flake- to granule-like morphology and the average particle size sharply decreased with in- creases in milling rotational speed and milling time. Moreover, a uniform dispersion of CNTs in AlSi10Mg powders was achieved only for a CNT content of 1.5wt%. Laser absorption values of the composite powders were also observed to gradually increase with the increase of CNT concentration, and different spectra displayed characteristic absorption peaks at a wavelength of approximately 826 nm.展开更多
基金Suppo rted by National Natural Science Foundation of China(Grant Nos.51975305,51905289)Major Research Project of Shandong Province of China(Grant Nos.2019GGX104040,2019GSF108236)+2 种基金Major Science and Technology Innovation Engineering Projects of Shandong Province of China(Grant No.2019JZZY020111)the Natural Scie nce Foundation of Shandong Province(Grant Nos.ZR2020KE027 and ZR2020ME158)Applied Basic Research Youth Project of Qingdao Science and Technology Plan of China(Grant No.19-6-2-63-cg).
文摘Aluminum alloy is the main structural material of aircraft,launch vehicle,spaceship,and space station and is processed by milling.However,tool wear and vibration are the bottlenecks in the milling process of aviation aluminum alloy.The machining accuracy and surface quality of aluminum alloy milling depend on the cutting parameters,material mechanical properties,machine tools,and other parameters.In particular,milling force is the crucial factor to determine material removal and workpiece surface integrity.However,establishing the prediction model of milling force is important and difficult because milling force is the result of multiparameter coupling of process system.The research progress of cutting force model is reviewed from three modeling methods:empirical model,finite element simulation,and instantaneous milling force model.The problems of cutting force modeling are also determined.In view of these problems,the future work direction is proposed in the following four aspects:(1)high-speed milling is adopted for the thin-walled structure of large aviation with large cutting depth,which easily produces high residual stress.The residual stress should be analyzed under this particular condition.(2)Multiple factors(e.g.,eccentric swing milling parameters,lubrication conditions,tools,tool and workpiece deformation,and size effect)should be considered comprehensively when modeling instantaneous milling forces,especially for micro milling and complex surface machining.(3)The database of milling force model,including the corresponding workpiece materials,working condition,cutting tools(geometric figures and coatings),and other parameters,should be established.(4)The effect of chatter on the prediction accuracy of milling force cannot be ignored in thin-walled workpiece milling.(5)The cutting force of aviation aluminum alloy milling under the condition of minimum quantity lubrication(mql)and nanofluid mql should be predicted.
文摘By adopting an equivalent geometry model of machining process and considering thermo-plastic properties of the work material, a finite element method(FEM) to study oblique milling process of aluminum alloy with a double-edge tool was presented. In the FEM, shear flow stress was determined by material test. Re-meshing technology was used to represent chip separation process. Comparing the predicted cutting forces with the measured forces shows the 3D FEM is reasonable. Using this FEM, chip forming process and temperature distribution were predicted. Chips obtained by the 3D FEM are in spiral shape and are similar to the experimental ones. Distribution and change trend of temperature in the tool and chip indicate that contact length between tool rake face and chip is extending as tool moving forward. These results confirm the capability of FEM simulation in predicting chip flow and selecting optimal tool.
文摘Nano-sized MoSi2 powder was produced successfully from commercially available MoSi2 by a mechanical milling process carried out for 100 h, and mechanical alloying was employed to synthesize AA 2024-MoSi2 nanocomposites, The effects of MoSi2 reinforcement and mechanical milling on the structure, morphology, and iron contamination of the produced materials were investigated using X-ray diffraction, scanning electron microscopy, and atomic absorption spectrometry. It is revealed that the morphology of the aluminum alloy changes continuously during milling from spherical to plate-like, irregular, and finally equiaxed. The presence of MoSi2 reinforcement accelerates the milling process and results in a smaller average particle size. The Williamson-Hall method determined that the crystallite size of the aluminum alloy in the composite powder is smaller than that of the unreinforced alloy at the same milling time and this size reaches 45 nm after 16 h milling time. The Fe contamination content is higher for the nanocomposite in comparison with the unreinforced alloy because of the wearing role of MoSi2 hard particles.
文摘Fatigue failure is one of the main failure forms of Al-Si-Cu-Mg aluminum alloys.To feature their mechanical aspect of fatigue behavior,the low-cycle fatigue behavior of permanent mold cast and die-cast Al-Si-Cu-Mg alloys at room temperature was investigated.The experimental results show that both permanent mold cast and die-cast Al-Si-Cu-Mg alloys mainly exhibit cyclic strain hardening.At the same total strain amplitude,the die-cast Al-Si-Cu-Mg alloy shows higher cyclic deformation resistance and longer fatigue life than does the permanent mold cast Al-Si-Cu-Mg alloy.The relationship between both elastic and plastic strain amplitudes with reversals to failure shows a monotonic linear behavior,and can be described by the Basquin and Coffin-Manson equations,respectively.
文摘This article mainly discussed bulk material prepared by powder metallurgy,and the commercial 2024 aluminum alloy powder and FeNiCrCoAl 3 high entropy alloy powder( both produced by argon gas atomization process) were ball-milled for different hours. The prepared powder was consolidated by hot extrusion method. The microstructures of the milled powder and bulk alloy were examined by X- Ray Diffraction( XRD), Scanning Electron Microscopy( SEM) and Transmission Electron Microscopy( TEM). The thermal stability was tested by differential scanning calorimetry( DSC). Mechanical properties of the extruded alloy were examined by Vickers hardness tester and mechanical testing machine. The results show that after milling,the mixed particle sizes and microstructures of the alloy powder change obviously. The compressive strength of the extruded alloy has reached 580 MPa under certain conditions of milling time and composition.
基金upported 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)+2 种基金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).
文摘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.
文摘Metal matrix composites （MMCs） with high specific stiffness, high strength, improved wear resistance, and thermal properties are being increasingly used in advanced structural, aerospace, automotive, electronics, and wear applications. Aluminum alloy-silicon carbide composites were developed using a new combination of the vortex method and the pressure die-casting technique in the present work. Machining studies were conducted on the aluminum alloy-silicon carbide （SiC） composite work pieces using high speed steel （HSS） end-mill tools in a milling machine at different speeds and feeds. The quantitative studies on the machined work piece show that the surface finish is better for higher speeds and lower feeds. The surface roughness of the plain aluminum alloy is better than that of the aluminum alloy-silicon carbide composites. The studies on tool wear show that flank wear increases with speed and feed. The end-mill tool wear is higher on machining the aluminum alloy-silicon carbide composites than on machining the plain aluminum alloy.
基金financially supported by the National Natural Science Foundation of China (No. 51405467)the Research Fund for Scientific and Technological Projects of Chongqing (Nos. 2012ggB 40003 and cstc2013yykfC 00006)
文摘This study investigated the effects of carbon nanotube （CNT） concentration on the micro-morphologies and laser absorption proper- ties of CNT/AlSi10Mg composite powders produced by high-energy ball milling. A scanning electron microscope, X-ray diffractometer, laser particle size analyzer, high-temperature synchronous thermal analyzer, and UV/VIS/NIR spectrophotometer were used for the analysis of micro- graphs, phases, granulometric parameters, thermal properties, and laser absorption properties of the composite powders, respectively. The results showed that the powders gradually changed from flake- to granule-like morphology and the average particle size sharply decreased with in- creases in milling rotational speed and milling time. Moreover, a uniform dispersion of CNTs in AlSi10Mg powders was achieved only for a CNT content of 1.5wt%. Laser absorption values of the composite powders were also observed to gradually increase with the increase of CNT concentration, and different spectra displayed characteristic absorption peaks at a wavelength of approximately 826 nm.
