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Mesoscale fabrication of a complex surface for integral impeller blades

Xibin WANG,Tianfeng ZHOU,Lijing XIE,Li JIAO,Zhibing LIU,Zhiqiang LIANG,Pei YAN

Frontiers of Mechanical Engineering 2017, Volume 12, Issue 1,   Pages 116-131 doi: 10.1007/s11465-017-0426-1

Abstract: A mesoscale component is usually manufactured by milling.However, a conventional milling tool cannot meet the machining requirements because of its size and stiffnessFor the fabrication of a complex integral impeller, a micro-ball-end mill is designed in accordance with

Keywords： mesoscale fabrication     micro-milling tool     mesoscale milling     impeller blade    

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3D finite element prediction of chip flow, burr formation, and cutting forces in micro end-milling of

A. DAVOUDINEJAD, P. PARENTI, M. ANNONI

Frontiers of Mechanical Engineering 2017, Volume 12, Issue 2,   Pages 203-214 doi: 10.1007/s11465-017-0421-6

Abstract: This study proposed a 3D finite element modeling (3D FEM) approach for the micro end-milling of Al6061FE modeling displayed notable advantages, such as capability to easily handle any type of tool geometry

Keywords： 3D finite element modeling     micro end-milling     cutting force     chip formation     burr formation    

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Development of meso-scale milling machine tool and its performance analysis

LI Hongtao, LAI Xinmin, LI Chengfeng, LIN Zhongqin, MIAO Jiancheng, NI Jun

Frontiers of Mechanical Engineering 2008, Volume 3, Issue 1,   Pages 59-65 doi: 10.1007/s11465-008-0005-6

Abstract: manufacturing such as MEMS and ultra precision machining, this paper focuses on the investigations on the meso millingprocess with a miniaturized machine tool.process mechanism studies are investigated based on the analysis of the characteristics of the meso millingThen, a meso-scale milling machine tool system is developed.Through test analysis, the meso milling process with a miniaturized machine tool is proved to be feasible

Keywords： applicable     machining mechanical     overview     positioning subsystem     miniaturized    

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Modeling of the minimum cutting thickness in micro cutting with consideration of the friction around

Tianfeng ZHOU, Ying WANG, Benshuai RUAN, Zhiqiang LIANG, Xibin WANG

Frontiers of Mechanical Engineering 2020, Volume 15, Issue 1,   Pages 81-88 doi: 10.1007/s11465-019-0561-y

Abstract: Friction modeling between the tool and the workpiece plays an important role in predicting the minimumcutting thickness during TC4 micro machining and finite element method (FEM) cutting simulation.friction modeling is proposed to illustrate the material flow mechanism around the friction zone in microcutting; estimate the stress distributions on the rake, edge, and clearance faces of the tool; and predictthe proposed friction model illustrates the relationship between the normal and sheer stress on the tool

Keywords： tool friction     minimum cutting thickness     finite element method     tool edge radius     micro cutting    

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Determination of the feasible setup parameters of a workpiece to maximize the utilization of a five-axis milling

Aqeel AHMED, Muhammad WASIF, Anis FATIMA, Liming WANG, Syed Amir IQBAL

Frontiers of Mechanical Engineering 2021, Volume 16, Issue 2,   Pages 298-314 doi: 10.1007/s11465-020-0621-3

Abstract: The machining industry must maximize the machine tool utilization for its efficient and effective usagefive-axis machine tools depends upon the cutting system’s geometry, the configuration of the machine toolmathematical model has been developed to determine the workpiece’s feasible location in the five-axis machine toolIn this research, a generic arrangement of the five-axis machine tool has been selected.The machine tool envelopes have been determined using the post-processor and axial limit.

Keywords： workpiece setup parameter     five-axis     space utilization     setup parameters     machine tool    

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Variable eccentric distance-based tool path generation for orthogonal turn-milling

Fangyu PENG,Wei WANG,Rong YAN,Xianyin DUAN,Bin LI

Frontiers of Mechanical Engineering 2015, Volume 10, Issue 4,   Pages 352-366 doi: 10.1007/s11465-015-0361-y

Abstract:

This study proposes an algorithm for maximizing strip width in orthogonal turn-milling based on variable

Keywords： orthogonal turn-milling     variable eccentric distance     local cutting profile     machining strip-width maximization    

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Five-axis rough machining for impellers

Ruolong QI, Weijun LIU, Hongyou BIAN, Lun LI

Frontiers of Mechanical Engineering 2009, Volume 4, Issue 1,   Pages 71-76 doi: 10.1007/s11465-009-0010-4

Abstract: An algorithm for determining the minimum distance between two surfaces is applied to estimate the toolThe tool axis vector is confirmed based on flank milling using a simple method that could eliminate globalinterference between the tool and the blades.

Keywords： five-axis     impeller     tool-path     planning     flank milling     ruled surface    

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Machinability of damage-tolerant titanium alloy in orthogonal turn-milling

Tao SUN, Lufang QIN, Junming HOU, Yucan FU

Frontiers of Mechanical Engineering 2020, Volume 15, Issue 3,   Pages 504-515 doi: 10.1007/s11465-020-0586-2

Abstract: However, cutting TC21 entails problems, such as high cutting temperature, high tool tip stress, rapidtool wear, and difficulty guaranteeing processing quality.optimize the cutting parameters of orthogonal turn-milling and improve the machining efficiency, toolThe mechanism of the effect of turn-milling parameters on tool life is discussed, the relationship betweeneach parameter and tool life is analyzed, and the failure process of a TiAlN-coated tool in turn-milling

Keywords： orthogonal turn-milling     damage-tolerant titanium alloy     tool life and failure     machined surface integrity    

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Micro-optical fabrication by ultraprecision diamond machining and precision molding

Hui LI, Likai LI, Neil J. NAPLES, Jeffrey W. ROBLEE, Allen Y. YI

Frontiers of Mechanical Engineering 2017, Volume 12, Issue 2,   Pages 181-192 doi: 10.1007/s11465-017-0444-z

Abstract: improvements in ultraprecision machine design and performance, particularly with the introduction of both slow tooland fast tool servo.In this paper, first ultraprecision machine design and machining processes such as slow tool and fast

Keywords： ultraprecision machining     slow tool servo     fast tool servo     compression molding     injection molding     microlens    

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Energy field-assisted high-speed dry milling green machining technology for difficult-to-machine metal

Frontiers of Mechanical Engineering 2023, Volume 18, Issue 2, doi: 10.1007/s11465-022-0744-9

Abstract: High-speed dry milling has emerged as a typical green processing technology due to its high processingHowever, the lack of necessary cooling and lubrication in high-speed dry milling makes it difficult tomeet the continuous milling requirements for difficult-to-machine metal materials.By analyzing the effects of changing the energy field and cutting parameters on tool wear, chip morphologyenergy-field-assisted milling of difficult-to-machine metal materials is demonstrated.

Keywords： difficult-to-machine metal material     green machining     high-speed dry milling     laser energy field-assistedmilling     ultrasonic energy field-assisted milling     cryogenic minimum quantity lubrication energy field-assistedmilling    

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Fiber-reinforced composites in milling and grinding: machining bottlenecks and advanced strategies

Frontiers of Mechanical Engineering 2022, Volume 17, Issue 2, doi: 10.1007/s11465-022-0680-8

Abstract: Milling and grinding arise as the preferred choices because of their precision processing.summarizes an up-to-date progress of the damage formation mechanisms and suppression strategies in millingFirst, the formation mechanisms of milling damage, including delamination, burr, and tear, are analyzedultrasonic vibration-assisted machining, cryogenic cooling, minimum quantity lubrication (MQL), and toolMQL shows its advantages in terms of reducing friction coefficient, force, temperature, and tool wear

Keywords： milling     grinding     fiber-reinforced composites     damage formation mechanism     delamination     material removal    

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Cutting Force Model for a Small-diameter Helical Milling Cutter

LI Xiwen, YANG Shuzi, YANG Mingjin, XIE Shouyong

Frontiers of Mechanical Engineering 2007, Volume 2, Issue 3,   Pages 272-277 doi: 10.1007/s11465-007-0047-1

Abstract: In the milling process, the major flank wear land area (two-dimensional measurement for the wear) ofa small-diameter milling cutter, as wear standard, can reflect actual changes of the wear land of theThe cutting force model for the helical milling cutter is validated by experiments.established in the research can provide a theoretical foundation for monitoring the condition of a millingprocess that uses a small-diameter helical milling cutter.

Keywords： computational     corresponding     helical milling     theoretical foundation     Characteristic    

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Position-varying surface roughness prediction method considering compensated acceleration in milling

Frontiers of Mechanical Engineering 2021, Volume 16, Issue 4,   Pages 855-867 doi: 10.1007/s11465-021-0649-z

Abstract: Machined surface roughness will affect parts’ service performance. Thus, predicting it in the machining is important to avoid rejects. Surface roughness will be affected by system position dependent vibration even under constant parameter with certain toolpath processing in the finishing. Aiming at surface roughness prediction in the machining process, this paper proposes a position-varying surface roughness prediction method based on compensated acceleration by using regression analysis. To reduce the stochastic error of measuring the machined surface profile height, the surface area is repeatedly measured three times, and Pauta criterion is adopted to eliminate abnormal points. The actual vibration state at any processing position is obtained through the single-point monitoring acceleration compensation model. Seven acceleration features are extracted, and valley, which has the highest R-square proving the effectiveness of the filtering features, is selected as the input of the prediction model by mutual information coefficients. Finally, by comparing the measured and predicted surface roughness curves, they have the same trends, with the average error of 16.28% and the minimum error of 0.16%. Moreover, the prediction curve matches and agrees well with the actual surface state, which verifies the accuracy and reliability of the model.

Keywords： surface roughness prediction     compensated acceleration     milling     thin-walled workpiece    

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Energy saving design of the machining unit of hobbing machine tool with integrated optimization

Frontiers of Mechanical Engineering 2022, Volume 17, Issue 3, doi: 10.1007/s11465-022-0694-2

Abstract: The machining unit of hobbing machine tool accounts for a large portion of the energy consumption duringAn integrated optimization model for reducing tool displacement and energy consumption is developed onResults show that the energy consumption and tool displacement of the machining unit are reduced, indicating

Keywords： energy saving design     energy consumption     machining unit     integrated optimization     machine tool    

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Effect of magneto rheological damper on tool vibration during hard turning

P. Sam PAUL, A. S. VARADARAJAN

Frontiers of Mechanical Engineering 2012, Volume 7, Issue 4,   Pages 410-416 doi: 10.1007/s11465-012-0341-4

Abstract: The present investigation aims at developing a magneto rheological (MR) fluid damper for suppressing toolwere conducted to arrive at a set of electrical, compositional and shape parameters that can suppress toolIt was observed that the use of MR fluid damper reduces tool vibration and improves the cutting performance

Keywords： tool vibration     magneto rheological damper     hard turning     surface finish     tool wear    

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Title Author Date Type Operation

Mesoscale fabrication of a complex surface for integral impeller blades

Xibin WANG,Tianfeng ZHOU,Lijing XIE,Li JIAO,Zhibing LIU,Zhiqiang LIANG,Pei YAN

Journal Article

3D finite element prediction of chip flow, burr formation, and cutting forces in micro end-milling of

A. DAVOUDINEJAD, P. PARENTI, M. ANNONI

Journal Article

Development of meso-scale milling machine tool and its performance analysis

LI Hongtao, LAI Xinmin, LI Chengfeng, LIN Zhongqin, MIAO Jiancheng, NI Jun

Journal Article

Modeling of the minimum cutting thickness in micro cutting with consideration of the friction around

Tianfeng ZHOU, Ying WANG, Benshuai RUAN, Zhiqiang LIANG, Xibin WANG

Journal Article

Determination of the feasible setup parameters of a workpiece to maximize the utilization of a five-axis milling

Aqeel AHMED, Muhammad WASIF, Anis FATIMA, Liming WANG, Syed Amir IQBAL

Journal Article

Variable eccentric distance-based tool path generation for orthogonal turn-milling

Fangyu PENG,Wei WANG,Rong YAN,Xianyin DUAN,Bin LI

Journal Article

Five-axis rough machining for impellers

Ruolong QI, Weijun LIU, Hongyou BIAN, Lun LI

Journal Article

Machinability of damage-tolerant titanium alloy in orthogonal turn-milling

Tao SUN, Lufang QIN, Junming HOU, Yucan FU

Journal Article

Micro-optical fabrication by ultraprecision diamond machining and precision molding

Hui LI, Likai LI, Neil J. NAPLES, Jeffrey W. ROBLEE, Allen Y. YI

Journal Article

Energy field-assisted high-speed dry milling green machining technology for difficult-to-machine metal

Journal Article

Fiber-reinforced composites in milling and grinding: machining bottlenecks and advanced strategies

Journal Article

Cutting Force Model for a Small-diameter Helical Milling Cutter

LI Xiwen, YANG Shuzi, YANG Mingjin, XIE Shouyong

Journal Article

Position-varying surface roughness prediction method considering compensated acceleration in milling

Journal Article

Energy saving design of the machining unit of hobbing machine tool with integrated optimization

Journal Article

Effect of magneto rheological damper on tool vibration during hard turning

P. Sam PAUL, A. S. VARADARAJAN

Journal Article