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This paper addresses the problems of easy deformation, difficult dimensional control and difficult accuracy assurance during the production of thin-walled gears for helicopter spoke cutting. It uses finite element simulation technology, metal cutting principles, process optimization and other design and manufacturing technologies to reveal the causes of cutting deformation, effectively predict the deformation of parts during cutting, and develop reasonable deformation control strategies. This study explores the effects of cutting force, residual stress and clamping method on gear machining deformation. The deformation of the spoke plate is analysed by finite element simulation. Abaqus software is adopted to establish a finite element model for 2D turning simulation to predict the machining residual stresses and cutting forces during gear turning machining with different cutting parameters. The simulated cutting forces are compared with the residual stresses and experimentally measured values to verify the accuracy of the finite element model and provide a theoretical basis for model construction in the next simulation study. With Abaqus software, the effect of different cutting forces on the deformation of the spoke plate is simulated, and the effect of the superposition of cutting and clamping forces on the deformation of the spoke plate is simulated using life and death cell technology to simulate the machining of the workpiece. Then, a corresponding fixture is designed to realise the corresponding clamping position for machining experiments, and the deformation of the spoke plate is measured by CMM (coordinate measuring machine) to verify the realism of the simulation. This research provides scientific theoretical guidance and process support for aerospace thin-walled gear spoke plate turning.

B 4 C particle-reinforced Al matrix composite (B 4 C p /Al) has excellent properties and is expected to become the mainstream of composites in the future. Due to the complex meso-structure of B 4 C p /Al, this increases the difficulty of material precision machining. In addition, the current research on the PRMMCs generally focuses on SiC p /Al and the effects of machining parameters on cutting force and temperature, while the research on the effects of tool geometry parameters on material cutting is relatively rare. Therefore, the cutting mechanism of B 4 C p /Al is studied by finite element simulation. Firstly, based on the meso-structure of B 4 C p /Al, a three-dimensional (3D) model of the material is established. Then the mechanism of surface formation of B 4 C p /Al was studied by combining cutting simulation and turning experiment. Use the simulation to study the effect of tool rake angle on material cutting surface quality. It was found that the removal mode of B 4 C particles, the residual stress in Al matrix after cutting, and the plastic deformation would be affected by the tool rake angle, thus affecting the cutting surface quality. After a comprehensive comparison, it is found that when the rake angle is − 5°, the cutting quality is the best.

Tool design is very important in the modern manufacturing industry. However, the traditional tool design process often has a heavy workload, which reduces the production efficiency of tool manufacturing enterprises. To deal with these problems, this paper proposes an integrated tool design platform to solve the problems in tool design. The tool-integrated design platform uses parametric modeling technology to allow design engineers to quickly create a geometric model of the tool by setting key parameters. The platform also introduces cutting simulation technology. Design engineers can perform simulation analysis on the platform and evaluate its performance and feasibility by simulating different tool design schemes. At the same time, this paper also uses cloud database technology to realize the function of multi-person remote collaborative design. In addition, the platform also uses genetic algorithm to optimize the cutting depth, cutting width, feed rate, and spindle speed of the tool with the minimum three-way milling force as the goal to guide the actual processing and production. In summary, by introducing technologies such as parametric modeling, parametric simulation, and cloud databases, enterprises can effectively solve the problems in the tool design process. The design time cycle is greatly shortened, and multi-person remote collaborative design becomes more convenient. This will significantly improve the enterprise’s production efficiency and help the tool’s precise design.

Cutting simulation is a crucial tool that enables engineers and operators to optimize machining processes virtually, before producing physical parts. The accuracy of these simulations relies heavily on validated models, encompassing both friction and material parameters. The prevalent technique for calibrating material models in cutting simulations is the inverse method. This state-of-the-art approach indirectly determines model parameters by comparing simulated outcomes with experimental data. However, the manual calibration process can be complex and time-consuming due to the intricacies of numerical simulation setups and the abundance of material model parameters. To address these challenges, this paper presents a novel fully-automated calibration approach utilizing multi-objective optimization algorithms. This approach integrates a modular design, simplifying the calibration process and enabling automatic calibration of any model parameters within cutting simulations. The approach has been successfully applied to calibrate the model parameters of AISI 1045 and X30CrMoN15-1 materials. Moreover, through a comparison of various optimization algorithms, this paper underscores the efficiency of the swarm optimizer in calibrating model parameters, particularly in scenarios with restricted computational resources.

Aiming at the machining difficulty of high-volume fraction SiCp/Al composites, the cutting mechanism and damage behavior of SiCp/Al composites with volume fraction of 65% during the milling process using PCD tools were studied in this paper. The complex deformation phenomena among SiC particles, Al matrix, and particle–matrix in the tool-particle contact area during cutting were analyzed. A two-dimensional finite element model of a cut SiC/Al composite was built, cohesive zone model (CZM) was adopted, and relevant experiments were conducted to validate its accuracy and the effectiveness of the model. The SiCp/Al composite containing 65% silicon carbide particles (SiCp) was cut using polycrystalline diamond tools. Then, the effects of processing parameters (tool rake angle γ 0 , corner radius r , milling depth a p , milling speed v ) and the tool-particle interaction on material properties were analyzed using a single-factor variable method. Both simulation and experiments revealed the failure modes of SiC particles and the Al matrix as well as the correlations with the cutting force, cutting temperature, cutting stress, and surface morphology. The results theoretically underlie the appropriate selection of tool geometrical parameters and the improved processability of SiCp/Al PCD tools.

A vacuum pump mainly consists of intermeshing screw rotors, which apply a cycloid profile to enhance the operating performance. However, it yields a concave rotor profile, increases the machining difficulty, and requires precision accuracy in the manufacturing process. This study proposes an analytical design of a particular whirling cutter and the rotor cutting method considering double tilt angles and assembly offset setting. The cutting simulation is demonstrated in analytical methods and virtual machining for various vacuum pump screw rotors. The analytical cutting result indicates that the overall lengthwise rotor profile deviation is identical. Besides, the virtual machining result indicates that the tooth surface topology is smooth and uniform, and the maximum profile deviation is still much more undersized than the grinding allowance. Moreover, the proposed method is still reliable for various vacuum pump rotors of Kashiyama type, Quimby type, Hanbell Precise Machinery P series, and Hanbell Precise Machinery P series with clearance design, where their delta deviations consistently tinier than 0.1 mm. Finally, it verifies that the proposed analytical design of the whirling cutter design, utilization of double tilt angles, and assembly offset setting are reliable for various vacuum pump rotors applying whirling milling machining.

In recent years, SiCp/Al metal matrix composites (MMCs) have attracted increasing attention from academia and industry. The size and distribution of particles in this material have an important effect on its actual performance. First, the geometric analysis of milling is performed. A two-dimensional micro finite element model consisting of hard SiC particles and a soft aluminum matrix is established to study the milling of SiCp/Al composites. In this paper, the cutting mechanism of SiCp/Al MMCs reinforced by a uniform distribution of particles of the same size and random distribution of non-equal size particles at the micron level was compared by using the finite element method and finite element model with a zero-thickness cohesive layer. The simulation results show that same-size particles are evenly distributed in the matrix, and good stress distribution and chip morphology can be obtained. In addition, the cutting force fluctuation is small, and the machining surface quality is good. The properties of Al-based SiC composites can be improved by evenly distributing same-size particles. Considering the particle size and distribution, the random model can more accurately simulate the chip, cutting force fluctuation of the workpiece, and workpiece surface damage than the uniform model. A good correlation between the research results and experimental results is shown in the literature.

Compared with other materials, high-volume fraction aluminum-based silicon carbide composites (hereinafter referred to as SiCp/Al) have many advantages, including high strength, small change in the expansion coefficient due to temperature, high wear resistance, high corrosion resistance, high fatigue resistance, low density, good dimensional stability, and thermal conductivity. SiCp/Al composites have been widely used in aerospace, ordnance, transportation service, precision instruments, and in many other fields. In this study, the ABAQUS/explicit large-scale finite element analysis platform was used to simulate the milling process of SiCp/Al composites. By changing the parameters of the tool angle, milling depth, and milling speed, the influence of these parameters on the cutting force, cutting temperature, cutting stress, and cutting chips was studied. Optimization of the parameters was based on the above change rules to obtain the best processing combination of parameters. Then, the causes of surface machining defects, such as deep pits, shallow pits, and bulges, were simulated and discussed. Finally, the best cutting parameters obtained through simulation analysis was the tool rake angle γ0 = 5°, tool clearance angle α0 = 5°, corner radius r = 0.4 mm, milling depth ap = 50 mm, and milling speed vc = 300 m/min. The optimal combination of milling parameters provides a theoretical basis for subsequent cutting.

High-speed machining is a practical way to attain high productivity with lower costs. Under this condition, the tool geometry needs to be optimized to sustain high cutting forces and temperatures. The sharpness of the cutting edge and the coating thickness (CT) are two key parameters that affect the tool’s performance. While a sharp edge eases the cutting process, it causes a high stress concentration, which increases the wear rate and eventual edge fracture. In this study, we use a combination of finite element simulations and experimental testing to evaluate the effects of CT ( 1–3 μm), edge radius ( r β , 6–15 μm), and coefficient of friction ( μ = 0 - 0.2 ) on the stress distribution at the cutting edge. Our simulations showed that the larger the CT, the higher the stress magnitude inside the coating, but the lower the maximum stress depth percentile. Considering an industrial case of cutting steel workpieces using AlCrN-coated tungsten carbide tools under given cutting parameters, our simulations suggested an optimum CT of 3 μm. By manufacturing a series of milling tools with different CTs and edge radii, we validated the simulation results using a set of well-controlled milling experiments. Finally, the edge radius should be selected considering the size of rake/flank angle mainly to control stress distribution over the cutting edge.

Improving the material removal rate (MRR) can significantly enhance the efficiency of the milling operations during machining. However, increasing MRR develops a larger degree of stress and eventual wear at the cutting edge, reducing the tool’s lifetime, in particular for hard metals like stainless steel. Therefore, it is important to optimize the tool geometry to enhance the stress-carrying capacity under extreme cutting conditions. Considering a four-fluted tungsten carbide milling tool for cutting stainless steel, we propose in this study a procedure for reducing tool stresses by modifying the tool geometry. Using a systematic set of finite element simulations, we showed that the degree of stresses on the cutting edge can be reduced by optimizing three geometrical parameters, i.e., helix angle, rake angle, and cutting edge radius. To validate the simulation results, we manufactured 18 four-fluted milling tools with varying geometries and tested them by milling stainless steel 316 L under identical cutting conditions. The performance of each tool was ranked based on microscopic inspections of their cutting edges, showing a close agreement with the numerical simulation predictions. This study presents a procedure for modifying milling tool geometry to enhance performance under extreme machining conditions.