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Carbon fiber–reinforced polymer (CFRP) composites are widely utilized in the aerospace industry due to their exceptional mechanical properties. In this paper, a regular dodecagon trajectory side milling method was employed to investigate the high-speed cutting performance of CFRP, focusing on the impact of fiber cutting angle, up milling and down milling, processing parameters, and cooling conditions on the cutting characteristics. Results indicate that utilizing the Gr-NMQL cutting lubrication method can significantly improve machining surface quality while reducing cutting force by up to 15%. Additionally, using a PCD burr milling cutter, the normal and tangential cutting forces followed a particular trend: 60° > 30° > 90° > 0° > 150° > 120°. Moreover, when the cutting speed exceeded 200m/min, both normal and tangential cutting forces showed a significant decrease. Cutting along the fiber direction yielded superior machining quality compared to it, and the optimal surface roughness was achieved when cutting along the 90° direction. Finally, a comparative study of up milling and down milling revealed that implementing the up milling process improved both cutting force and surface quality. These findings contribute to a deeper understanding of the high-speed milling performance of CFRP and provide insights for optimizing the machining process. [ABSTRACT FROM AUTHOR]

Deep-holes are typical parts of aircraft structures, which is difficult to be machined. Boring assisted with ultrasonic vibration-assisted cutting has been proved to greatly enhance machining performance, especially for Ti6Al4V aviation alloy. This paper focuses on the machining extra-large aspect ratio (exceeding 20) of Ti6Al4V aviation deep-hole with the axial ultrasonic vibration-assisted boring (AUVB) method. First, the kinetics of the AUVB process is analyzed and a retrospective of its separation cutting feature is provided. Subsequently, a multi-stepped cantilever beam model of boring bar is established to analyze its static rigidity and dynamic stability. The aperture error is deduced, and then size coefficient is put forward to represent the static rigidity of the boring bar, which is inversely proportional to the diameter. In addition, two different vibration cases, namely modal-coupling vibration and regenerative vibration are considered for dynamic stability analysis. Next, the morphology of bored surface is analyzed, and the geometric height of peaks formed by AUVB and CB are calculated. Phase shift φ= π is suggested for obtaining a better surface in AUVB. Finally, the feasibility of AUVB on the machining of extra-large aspect ratio Ti6Al4V titanium alloy aviation deep-hole is verified through systematic experiments. Results demonstrate that AUVB has obvious advantages in reducing boring force, improving boring accuracy, suppressing vibration and promoting surface quality. Furthermore, the aperture error decreases to 50% and vibration amplitudes decrease to only 20–25%. The overall surface roughness of the deep-hole part stays below Ra=0.8μm with rotational speeds of 60r/min and 80r/min, and the surface residual stress state is transferred from the tensile state to a compressive one. As a result, not only AUVB can provide better boring accuracy and surface finish, but it also can enhance the surface fatigue properties. [ABSTRACT FROM AUTHOR]

Axial ultrasonic vibration-assisted cutting (AUVC) has been proved to have better machining performance compared with conventional cutting methods; however, the effect of numerous and complex influencing factors on machining performance has not been clearly revealed, and a recommended combination of cutting conditions has not been proposed yet, especially for difficult-to-machine material such as Ti6Al4V alloy. This paper focuses on the experimental and theoretical investigation into Ti6Al4V machining performance with AUVC method. First, a retrospective of the separation characteristics of AUVC is provided, and the variable parameter cutting characteristics are demonstrated. The influencing factors on machining performance are classified into four categories: machining parameters, vibration parameters, tool choice, and cooling conditions. The relationship between these factors in terms of their effect on machining performance is established theoretically. Then, it describes experiments to determine the influence of these factors on cutting force, tool life, and surface roughness. For absolute influence, the orders for cutting force, tool life, and surface roughness are respectively cutting depth > amplitude > feed rate > rotation speed, rotation speed > feed rate > amplitude > cutting depth, and feed rate > amplitude > cutting depth > rotation speed. However, for relative influence, the order is unified as amplitude > feed rate > rotation speed > cutting depth. Finally, it suggests a smaller feed rate, larger amplitude, moderate rotation speed, and smaller cutting depth in addition to a WC tool coated with TiAlN and used under HPC cooling condition for optimal performance of AUVC. This recommendation is based on the theoretical analysis and experimental results of cutting force, surface roughness, and tool life. [ABSTRACT FROM AUTHOR]

Axial ultrasonic vibration–assisted cutting has been proposed and proved preponderance on cutting performance; however, the transient separation cutting characteristic has not been clearly revealed. This paper focuses on the transient separation cutting characteristic of axial ultrasonic vibration–assisted cutting and its influence on the cutting performance. First, the separation cutting criteria, including feed coefficient and phase shift, are established and influence factors, such as feed rate, amplitude, and phase shift, are systematically analyzed. Subsequently, the duty ratio is deduced and calculated, and some features and a control mechanism are introduced. In addition, a transient separation cutting model with four stages is demonstrated. The reason for the average cutting force reduction by the transient separation cutting characteristic is also stated. Finally, the verification of the separation cutting and transient separation cutting model and the comparison of the feed thrust force and parameter influences on the cutting performance are experimentally performed. The transient signals of different duty ratios 0.55 to 1 are obtained, and 10 to 40% reductions of feed thrust are measured both by a PCB sensor and a Kistler dynamometer. The influence degree of the feed coefficient, spindle rotation speed, and cutting depth on the performance is analyzed. A parameter combination of smaller feed coefficient, moderate spindle rotation speed, and smaller cutting depth is suggested to obtain a better cutting performance by fully considering the cutting force, surface roughness, and tool life. [ABSTRACT FROM AUTHOR]

Three-dimensional Hashin failure criterion and material stiffness degradation model were compiled by VUMAT subroutine. The Abaqus/Explicit solver was performed to establish progressive damage model of cutting force for CFRP high-speed milling, and high-speed milling experiments with different cutting parameters were carried out. Further, the impact mechanism of fiber cutting angle and cutting parameters on cutting force, stress, and material failure during milling was explored, and the material removal mechanism in high-speed milling of CFRP was revealed. The results show that the error between the experimental and simulated of cutting forces is less than 5%, which indicates that the progressive damage model is feasible. The fiber cutting angle has significant influence on cutting force and stress in cutting process, and the cutting direction has a significant influence on cutting force. In addition, cutting parameters play a critical role in cutting force, and the feed per tooth is the most significant factor affecting the cutting force. Simultaneously, the progressive damage model predicts that the shear failure of materials mainly concentrates in the cutting area and extends along the feed direction. Finally, the material removal mechanism of CFRP in high-speed milling was revealed combining cutting force experiment. [ABSTRACT FROM AUTHOR]

In order to solve the problems of serious heating and easy ablation of conductive shaft in electrochemical machining of special-shaped deep hole with large aspect ratio, the two schemes of single-sided copper bar and symmetrical copper bar of conductive shaft are studied by ANSYS software. By establishing the thermoelectric coupling model of the conductive shaft, the distribution law of temperature field and thermal deformation of conductive shaft under different working conditions is analyzed. The conductive shaft structure based on symmetrical copper bar scheme is determined. Monitoring points are set at the key parts of the conductive shaft, and the temperature field distribution is verified by using the data acquisition card. The temperature acquisition results are consistent with the simulation results. Through the machining test of special-shaped inner spiral deep hole parts with large aspect ratio, the results show that under the conditions of working current of 15 000 A, feed rate of 5 mm/min, and continuous machining for 14 h, the forming accuracy of the workpiece is ± 0.15 mm and the surface roughness is better than Ra0.8 μm. The performance of the conductive shaft is stable and meets the actual processing requirements. The heat dissipation performance of the conductive shaft is optimized by providing air flow on the upper surface and side at the same time. [ABSTRACT FROM AUTHOR]

In order to solve the problem of uneven gap distribution and flow pattern in the complex parts with multi-stage internal cone hole in electrochemical machining, a method of computer simulation–assisted cathode design is proposed. The electric field and flow field models of machining gap are established respectively, and the simulations of different cathode profiles are carried out. When the cathode cone angle is 2°, the electric field distribution between the cathode and the workpiece is reasonable, and the electrolyte distribution in the machining gap is uniform. With the conditions of processing voltage 10 V, electrolyte inlet pressure 1.5 MPa, electrolyte temperature 28 ℃, and cathode feed speed 5 mm/min, the electrochemical machining (ECM) processing of multi-stage internal cone hole is carried out by using the optimized cathode. The results show that the surface of the workpiece has no flow pattern, the dimensional forming accuracy is better than 0.1 mm, and the surface roughness reaches Ra 0.697 μm. Research shows that the optimization of cathode structure with computer simulation can shorten the cathode development cycle and reduce the cost of cathode design effectively in ECM, which provides an efficient and feasible method for the optimization of complex cathode structure. [ABSTRACT FROM AUTHOR]

As a relatively new grinding technology, ELID (electrolytic in-process dressing) is widely used in some businesses. The oxide layer plays an important role in ELID grinding performance. The purpose of this work is to investigate the state of the oxide layer on ELID grinding wheel surfaces based on workpiece-cathode and tool-cathode. The thickness and surface topography of the oxide layer were measured from ELID grinding experiments based on workpiece-cathode and tool-cathode in different controlled dressing current. The normal grinding force was also compared in ELID grinding with workpiece-cathode and tool-cathode. According to the results, there are some caves on the surface of the oxide layer in ELID grinding with workpiece-cathode. With increasing controlled dressing current, the surface of the oxide layer becomes discontinuous in ELID grinding with workpiece-cathode. And the surface of the oxide layer becomes smoother with increasing controlled dressing current in ELID grinding with tool-cathode. Meanwhile, it was found that the oxide layer in ELID grinding with workpiece-cathode is thicker than that in ELID grinding with tool-cathode. Moreover, the normal grinding force in ELID grinding with workpiece-cathode is smaller than that in ELID grinding with tool-cathode. The results are helpful to improve the ELID grinding performance and apply ELID grinding technology with workpiece-cathode to abroad industrial applications. [ABSTRACT FROM AUTHOR]