Efficient layered plunge milling with low tool wear rate for axial flow impeller machining

Efficient layered plunge milling with low tool wear rate for axial flow impeller machining | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Efficient layered plunge milling with low tool wear rate for axial flow impeller machining Nuodi Huang, Yulei Ji, Hao Chen, Yuhan Wang, Limin Zhu This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-9050316/v1 This work is licensed under a CC BY 4.0 License Status: Under Review Version 1 posted 4 You are reading this latest preprint version Abstract Plunge milling is an efficient rough milling strategy of deep and narrow passages with difficult-to-cut material, due to its high axial stiffness and vibration suppression capability. However, for axial flow impellers with quasi-fan-shaped passages, uneven distribution of the radial cutting width in each plunge cycle commonly exists, which could not fully utilizing the cutting performance of the tool. This work proposes an efficient plunge milling strategy for five-axis rough machining of axial flow impeller passages. By dividing each passage section into upper and lower layers, the average radial cutting width is increased. To achieve maximum material removal rate, a quadratic optimization algorithm is designed to determine the optimal layering radius for each section under multiple geometric constraints. In addition, to decrease the excessive tool engagement angle caused by blade twisting at some plunge positions, a strategy for adjusting the plunge position sequence is proposed. Experimental validation is conducted on plunge roughing of a stainless-steel axial flow impeller. Experimental results show that compared with the conventional section-by-section plunge milling strategy, the proposed method can improve machining efficiency by 9.9%, and decrease the number of cutting edge pairs from 6 to 4. Plunge milling five-axis machining axial flow impeller layered strategy plunge sequence optimization Full Text Cite Share Download PDF Status: Under Review Version 1 posted Reviewers agreed at journal 16 Mar, 2026 Reviewers invited by journal 16 Mar, 2026 Editor assigned by journal 11 Mar, 2026 First submitted to journal 09 Mar, 2026 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-9050316","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":606722727,"identity":"69217542-0edc-47a9-b401-28b6726d4aa1","order_by":0,"name":"Nuodi Huang","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAAzklEQVRIiWNgGAWjYDACCTBpw8DYAKLZiNeSxsDYRqKWw1DVxGgxl+4x/Fzw67w98/weA4YPZYcZ+Gc34NdiOeeMsfTMvtuJjW08Bowzzh1mkLhzAL8Wgxs5BtK8PbcTGIFamHnbDjMYSCQQ1GL8m7fnnD1Yy18itZhJ8/w4wAhyGDMjcVrSyqx5G5KBfkkrONhzLp1H4gZBLcmbb/P8sbM3bD688cGPMms5/hkEtIABKBoNGxgYDgDZPESoB4E/DAzyRCodBaNgFIyCEQgAxQFBH5/i4HIAAAAASUVORK5CYII=","orcid":"https://orcid.org/0000-0003-2257-7516","institution":"Shanghai Jiao Tong University","correspondingAuthor":true,"prefix":"","firstName":"Nuodi","middleName":"","lastName":"Huang","suffix":""},{"id":606722728,"identity":"846a8a52-39fa-4efc-8327-3db44d5e1333","order_by":1,"name":"Yulei Ji","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Yulei","middleName":"","lastName":"Ji","suffix":""},{"id":606722729,"identity":"141362ca-5be0-424b-985a-d804730da779","order_by":2,"name":"Hao Chen","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Hao","middleName":"","lastName":"Chen","suffix":""},{"id":606722730,"identity":"3811b3c3-f263-4a1d-bd10-fe295c7f0a7d","order_by":3,"name":"Yuhan Wang","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Yuhan","middleName":"","lastName":"Wang","suffix":""},{"id":606722731,"identity":"b514ed77-737d-4602-8b10-b88cba6d751e","order_by":4,"name":"Limin Zhu","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Limin","middleName":"","lastName":"Zhu","suffix":""}],"badges":[],"createdAt":"2026-03-06 11:58:33","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-9050316/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-9050316/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":105033936,"identity":"858d945f-98ed-4574-b286-908c9badb590","added_by":"auto","created_at":"2026-03-20 07:22:11","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":695963,"visible":true,"origin":"","legend":"","description":"","filename":"Manuscript.pdf","url":"https://assets-eu.researchsquare.com/files/rs-9050316/v1_covered_1128066c-f897-42c9-9444-aa366755c603.pdf"}],"financialInterests":"","formattedTitle":"Efficient layered plunge milling with low tool wear rate for axial flow impeller machining","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false},"keywords":"Plunge milling, five-axis machining, axial flow impeller, layered strategy, plunge sequence optimization","lastPublishedDoi":"10.21203/rs.3.rs-9050316/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-9050316/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003ePlunge milling is an efficient rough milling strategy of deep and narrow passages with difficult-to-cut material, due to its high axial stiffness and vibration suppression capability. However, for axial flow impellers with quasi-fan-shaped passages, uneven distribution of the radial cutting width in each plunge cycle commonly exists, which could not fully utilizing the cutting performance of the tool. This work proposes an efficient plunge milling strategy for five-axis rough machining of axial flow impeller passages. By dividing each passage section into upper and lower layers, the average radial cutting width is increased. To achieve maximum material removal rate, a quadratic optimization algorithm is designed to determine the optimal layering radius for each section under multiple geometric constraints. In addition, to decrease the excessive tool engagement angle caused by blade twisting at some plunge positions, a strategy for adjusting the plunge position sequence is proposed. Experimental validation is conducted on plunge roughing of a stainless-steel axial flow impeller. 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