Modelling and optimization of magnesium alloy milling parameters

In the pursuit to lighter, less consuming products, manufacturers, especially in aviation and automotive industries, are turning more and more to using lightweight alloys such as the ones based on magnesium. Higher requirements for increased productivity have led to concepts like high-speed machining (HSM), high feed machining (HFM) or high-efficiency machining. Tighter regulations concerning requiring for more environmentally friendly industrial processes led to limitations in the use of cooling liquids and a search for cooling methods with less impact (dry cutting, cryogenic cooling, near dry machining and others). Better machining processes can only be achieved by modelling and optimization. This paper briefly presents the results obtained by our research team concerning the modelling and optimization attempts on face milling of magnesium alloys using different methods: design of experiments (e.g. factorial design, response surface method), fuzzy logic or neural networks.

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A Study of Cutting Forces in High-Speed Dry Milling of Inconel 718

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.500.105 ◽

2012 ◽

Vol 500 ◽

pp. 105-110 ◽

Cited By ~ 2

Author(s):

Huai Zhong Li ◽

Jun Wang

Keyword(s):

Cutting Forces ◽

Inconel 718 ◽

High Speed ◽

Cutting Speed ◽

High Yield ◽

Dry Milling ◽

Machining Processes ◽

Dry Cutting ◽

High Tendency ◽

Coated Carbide

nconel 718 is one of the most commercially important superalloys but with very poor machinability. It has a very high yield stress and a high tendency to adhesion and work-hardening. A recent trend of improving the machining processes of difficult-to-cut materials is to move towards dry cutting operations. This paper presents an experimental study of the cutting forces in high speed dry milling of Inconel 718 using a milling cutter with coated carbide inserts. It is found that the peak cutting forces increase with an increase in chip load in a nonlinear way, but cutting speed does not show a significant influence on the cutting force for the range of cutting speeds tested in this study.

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Investigation into High-Speed/Super-High Speed Grinding

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.189-193.4108 ◽

2011 ◽

Vol 189-193 ◽

pp. 4108-4111 ◽

Cited By ~ 1

Author(s):

Ya Li Hou ◽

Chang He Li ◽

Guo Yu Liu

Keyword(s):

Surface Integrity ◽

High Speed ◽

High Efficiency ◽

Dimensional Accuracy ◽

Abrasive Machining ◽

Machining Processes ◽

Finishing Process ◽

Key Technologies ◽

High Speed Grinding ◽

Advanced Machining

Abrasive machining is a widely employed finishing process for different-to-cut materials such as metals, ceramics, glass, rocks, etc to achieve close tolerances and good dimensional accuracy and surface integrity. High speed and super-high speed abrasive machining technologies are newest developed advanced machining processes to satisfy super-hardness and difficult-to-machining materials machined. In the present paper, high-speed/super-high speed abrasive machining technologies relate to ultra high speed grinding, quick-point grinding, high efficiency deep-cut grinding were analyzed. The efficiency and parameters range of these abrasive machining processes were compared. The key technologies and the newest development and current states of high speed and super-high speed abrasive machining were investigated. It is concluded that high speed and super-high speed abrasive machining are a promising technology in the future.

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Investigation into the Grindability and Surface Integrity of the Nickel Base Superalloy Using Liquid Nitrogen Jet Grinding

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.426-427.49 ◽

2010 ◽

Vol 426-427 ◽

pp. 49-54 ◽

Cited By ~ 1

Author(s):

Chang He Li ◽

Ya Li Hou ◽

Yu Cheng Ding

Keyword(s):

Surface Integrity ◽

High Speed ◽

Ground Surface ◽

Cryogenic Cooling ◽

Cutting Fluid ◽

Nickel Base Superalloy ◽

Grinding Process ◽

Machining Processes ◽

Grinding Conditions ◽

Nickel Base

Grinding processes are mainly technique employed widely as a finishing process in a variety of materials, such as metals, hardness and brittleness and ductile materials machining to achieve good dimensional and form accuracy of the product with acceptable surface integrity. However, grinding is associated with high specific energy requirements which may be an order higher than that required in other conventional machining processes such as turning, planning, milling etc. Therefore, in grinding process, high grinding zone temperature may lead to thermal damage to the work surface, induces micro-cracks and tensile residual stresses at the ground surfaces, which deteriorate surface quality and integrality of the ground surface. Therefore, grinding fluids are applied in different forms to control such high temperature, but they are ineffective, especially under high speed grinding conditions where the energy of the fluid is not sufficient to penetrate the boundary layer of air surrounding the wheel. Moreover, the conventional flood supply system demands more resources for operation, maintenance, and disposal, and results in higher environmental and health problems. Therefore, there are critical needs to reduce the use of cutting fluid in grinding process, and cryogenic cooling grinding is a promising solution. The work presented in this paper aims at evaluating the grind ability and surface integrity of the nickel base super alloy resulting from the application of cryogenic cooling.

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Application and Development of High-Efficiency Abrasive Finishing

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.189-193.3113 ◽

2011 ◽

Vol 189-193 ◽

pp. 3113-3116

Author(s):

Chang He Li ◽

Ling Yun Qi ◽

Hua Yang Zhao

Keyword(s):

High Speed ◽

High Performance ◽

High Efficiency ◽

Removal Rate ◽

Grinding Wheel ◽

Abrasive Machining ◽

Machining Processes ◽

Belt Grinding ◽

Hard And Brittle Materials ◽

High Removal Rate

High-efficiency abrasive machining is one of the important technology of advanced manufacture. Combined with raw and finishing machining, it can attain high removal rate like turning, milling and planning. The difficult-to-grinding materials can also be ground by means of this method with high performance. In the present paper, development status and latest progresses on high efficiency abrasive machining technologies relate to high speed and super-high speed grinding, high efficiency deep-cut grinding, hard and brittle materials high-efficiency grinding, powerful grinding and belt grinding were summarized. The efficiency and parameters range of these abrasive machining processes were compared. The key technologies of high efficiency abrasive machining, including grinding wheel, spindle and bearing, grinder, coolant supplying, installation and orientation of wheel and workpiece and safety defended, as well as intelligent monitor and NC grinding were investigated.

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The Application of Cryogenic Pneumatic Mist Jet Impinging in High-Speed Milling of Ti-6Al-4V

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.315-316.244 ◽

2006 ◽

Vol 315-316 ◽

pp. 244-248 ◽

Cited By ~ 4

Author(s):

Qing Long An ◽

Yu Can Fu ◽

Jiu Hua Xu

Keyword(s):

High Pressure ◽

High Speed ◽

High Efficiency ◽

Air Cooling ◽

High Speed Milling ◽

Cold Air ◽

Cutting Zone ◽

Cooling Effects ◽

Cooling Technology ◽

Cooling Methods

To solve the problems caused by high temperature in the cutting zone during high-speed milling of Titanium alloys, some cooling methods are employed, such as cold air cooling, high pressure coolant jet impinging, MQL, etc. But all have their shortfalls, both in cooling efficiency and environmental pollution. Here a new high efficiency cooling technology-cryogenic pneumatic mist jet impinging (CPMJI) cooling technology is offered. In this technology, a little quantity of coolant is carried by high pressure cryogenic air (-20) and reaches the machining zone in the form of mist jet. This paper mainly focuses on the cooling effects of CPMJI in high-speed milling of Titanium alloy Ti-6Al-4V, as compared with dry, cold air cooling and MQL conditions. CPMJI greatly reduced the temperature in cutting zone and flank wear of tool.

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Studying The Effect of a New Mixed Cutting Fluid on Surface Roughness

Engineering and Technology Journal ◽

10.30684/etj.v38i11a.1516 ◽

2020 ◽

Vol 38 (11A) ◽

pp. 1593-1601

Author(s):

Mohammed H. Shaker ◽

Salah K. Jawad ◽

Maan A. Tawfiq

Keyword(s):

Surface Roughness ◽

Stainless Steel ◽

Cutting Parameters ◽

Machining Process ◽

Cutting Fluid ◽

Depth Of Cut ◽

Cutting Fluids ◽

Machining Processes ◽

Dry Cutting ◽

Cutting Speeds

This research studied the influence of cutting fluids and cutting parameters on the surface roughness for stainless steel worked by turning machine in dry and wet cutting cases. The work was done with different cutting speeds, and feed rates with a fixed depth of cutting. During the machining process, heat was generated and effects of higher surface roughness of work material. In this study, the effects of some cutting fluids, and dry cutting on surface roughness have been examined in turning of AISI316 stainless steel material. Sodium Lauryl Ether Sulfate (SLES) instead of other soluble oils has been used and compared to dry machining processes. Experiments have been performed at four cutting speeds (60, 95, 155, 240) m/min, feed rates (0.065, 0.08, 0.096, 0.114) mm/rev. and constant depth of cut (0.5) mm. The amount of decrease in Ra after the used suggested mixture arrived at (0.21µm), while Ra exceeded (1µm) in case of soluble oils This means the suggested mixture gave the best results of lubricating properties than other cases.

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One-step Separation and Purification of Four Phenolic Acids from Stenoloma chusanum (L.) Ching by Medium-pressure Liquid Chromatography and High-speed Counter-current Chromatography

The Natural Products Journal ◽

10.2174/2210315508666181004115422 ◽

2019 ◽

Vol 9 (2) ◽

pp. 138-143

Author(s):

Tianyun Li ◽

Xiling Dai ◽

Yichen Li ◽

Guozheng Huang ◽

Jianguo Cao

Keyword(s):

Natural Products ◽

Liquid Chromatography ◽

Phenolic Acids ◽

High Speed ◽

High Efficiency ◽

Total Phenolic ◽

Medium Pressure ◽

Medium Pressure Liquid Chromatography ◽

One Step ◽

Counter Current

Background:Stenoloma chusanum (L.) Ching is a Chinese traditional medicinal fern with high total flavonoid and total phenolic content. Traditionally, phenolic compounds were separated by using column chromatography, which is relatively inefficient. </P><P> Objective: This study aims to use an efficient method to separate natural products from S. chusanum by Medium-Pressure Liquid Chromatography (MPLC) and High-Speed Counter-Current Chromatography (HSCCC).Methods:In the present research, firstly, a sample (2.5 g) from the dichloromethane extract of S. chusanum was separated by MPLC. Next, fraction P5 was purified by HSCCC with a two-phase solvent system composed of hexane-ethyl acetate-methanol-water (HEMWat) at a volume ratio of 2:4:1:4 (v/v/v/v). </P><P> Result: Four phenolic acids were obtained and their structures were identified by means of NMR and ESI-mass analysis. They were identified as: 1) protocatechuic acid (34 mg, purity 90.1%), 2) syringic acid (66 mg, purity 99.0%), 3) p-hydroxybenzoic acid (5 mg, purity 91.2%) and 4) vanillic acid (6 mg, purity 99.3%).Conclusion:The combination of MPLC and HSCCC is a high-efficiency separation method for natural products. This is the first report with regard to the separation of four phenolic acids in one step by MPLC and HSCCC from S. chusanum (L.) Ching.

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On-chip trans-dimensional plasmonic router

Nanophotonics ◽

10.1515/nanoph-2020-0078 ◽

2020 ◽

Vol 9 (10) ◽

pp. 3357-3365 ◽

Cited By ~ 1

Author(s):

Shaohua Dong ◽

Qing Zhang ◽

Guangtao Cao ◽

Jincheng Ni ◽

Ting Shi ◽

...

Keyword(s):

High Speed ◽

High Efficiency ◽

Incident Angle ◽

Reciprocal Lattice ◽

Plasmonic Waveguide ◽

Optical Diffraction ◽

Local Dynamic ◽

Phase Gradient ◽

On Chip ◽

Plasmon Polaritons

AbstractPlasmons, as emerging optical diffraction-unlimited information carriers, promise the high-capacity, high-speed, and integrated photonic chips. The on-chip precise manipulations of plasmon in an arbitrary platform, whether two-dimensional (2D) or one-dimensional (1D), appears demanding but non-trivial. Here, we proposed a meta-wall, consisting of specifically designed meta-atoms, that allows the high-efficiency transformation of propagating plasmon polaritons from 2D platforms to 1D plasmonic waveguides, forming the trans-dimensional plasmonic routers. The mechanism to compensate the momentum transformation in the router can be traced via a local dynamic phase gradient of the meta-atom and reciprocal lattice vector. To demonstrate such a scheme, a directional router based on phase-gradient meta-wall is designed to couple 2D SPP to a 1D plasmonic waveguide, while a unidirectional router based on grating metawall is designed to route 2D SPP to the arbitrarily desired direction along the 1D plasmonic waveguide by changing the incident angle of 2D SPP. The on-chip routers of trans-dimensional SPP demonstrated here provide a flexible tool to manipulate propagation of surface plasmon polaritons (SPPs) and may pave the way for designing integrated plasmonic network and devices.

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Energy assessment of different cooling technologies in Ti-6Al-4V milling

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-020-06575-1 ◽

2021 ◽

Vol 112 (11-12) ◽

pp. 3279-3306

Author(s):

Paolo Albertelli ◽

Michele Monno

Keyword(s):

Energy Performance ◽

Primary Energy ◽

Cryogenic Cooling ◽

Model Parameters ◽

Tribological Behaviour ◽

Dry Cutting ◽

Sustainable Solutions ◽

Energy Assessment ◽

Energy Models ◽

Conventional Cooling

AbstractManufacturing craves for more sustainable solutions for machining heat-resistant alloys. In this paper, an assessment of different cooling lubrication approaches for Ti6Al4V milling was carried out. Cryogenic cutting (liquid nitrogen) and conventional cooling (oil-based fluid) were assessed with respect to dry cutting. To study the effects of the main relevant process parameters, proper energy models were developed, validated and then used for comparing the analysed cooling lubrication strategies. The model parameters were identified exploiting data from specifically conceived experiments. The power assessment was carried out considering different perspectives, with a bottom-up approach. Indeed, it was found that cryogenic cooling, thanks to a better tribological behaviour, is less energy demanding (at least 25%) than dry and conventional cutting. If the spindle power is considered, lower saving percentages can be expected. Cryogenic cooling showed its best energy performance (from 3 to 11 times) with respect to conventional cutting if the machine tool perspective is analysed. Considering even the primary energy required for producing the cutting fluids, the assessment showed that cryogenic cooling requires up to 19 times the energy required for conventional cutting.

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