Progress in the milling processes for molten coatings: A review

Abstract

In this paper, we provide a summary of six output variables in the milling process. These variables include cutting force, tool wear, surface roughness, surface burr, residual stress, and microhardness. The cutting force has an impact on the power consumption during the cutting process and serves as a reflection of the cutting state. The tool wear degree determines the performance of cladding layer after milling. Surface roughness and surface burrs can affect the surface quality and final use of the workpiece after milling. Excessive residual stress can cause distortion, deformation, and even cracking of the parts. Microhardness is used to evaluate the service life and reliability of materials. Examined the various influencing factors on the six output variables’ influence. These various influencing factors not only impact the output variables, but also affect the cutting state, workpiece surface quality, tool life, and other aspects of the cutting process. The generalization of the various influencing factors primarily encompasses various milling parameters, cutting directions, treatments of the fused cladding layer, construction orientations of the fused coating layer, and machinability of the fused coating layer. By studying the output variables and influencing factors of molten cladding milling, researchers have gained a more comprehensive understanding of this process. Ultimately, they have also forecasted future development directions for molten cladding milling, the utilization of ultrasonic vibration machining, Electrical Discharge Machining assisted machining, and computer simulation technology in cladding layer milling shows promising development prospects.