Feed Velocity Research Articles

Treatment of mariculture wastewater by an integrated ultrasonic stripping-membrane distillation (US-MD) system: Effect of operating parameters on effluent quality and membrane fouling mitigation

The actual application of membrane distillation (MD) in the mariculture industry is faced with two challenges of substandard ammonia removal and membrane fouling. Therefore, an integrated ultrasonic stripping (US)-MD system is built to efficiently purify mariculture wastewater in this study. US-MD technique exhibited outstanding purification for NH4+-N (86.8 %) compared to sole MD (76.2 %). US pretreatment coupled with a phase of setting ahead of MD could notably remove organics and salts from sewage, finally mitigating membrane fouling in subsequent MD (normalized flux (NF), 96.0 h, 0.77) compared sole MD (0.19). Ultrasonic cavitation effect in US unit largely promoted the protein denaturation and salt crystallization, causing a considerable removal efficiency for proteins (54.0 %∼68.8 %) and phosphate (7.1 %∼8.7 %) before MD unit. The operating parameters of US-MD system posed remarkable impacts on its purification efficiency, and proper increment of pH, operation time, and ultrasonic power in US unit partly facilitated the US-MD operation. US-MD operation was also enhanced by slightly raising the US temperature to around 35 °C. Furthermore, the higher temperature (80–90 °C) and flow velocity (10.48–15.72 mm/s) of feed in MD unit also contributed to the efficient purification of mariculture wastewater.

Parametric Analysis of Cylinder Drying Process in Association with Various Materials

In this study, the heat and mass transfers in the fabric drying process of a single-cylinder dryer are numerically examined in detail by using MATLAB codes and illustrating 3D velocity and temperature profiles obtained by a CFD-ACE+ software package. Seven different drying materials including Polyethylene terephthalate (PET), Polyethylene, Polypropylene, Cotton, Wool, Rayon, and Nylon are employed as drying materials. Influences of the drying-material thickness, contacting percentage, cylinder temperature, feeding velocity, and cylinder diameter are examined in detail. For all cases in this study, it is found that the maximum temperature of the drying material in the drying process is strongly dependent on the thermal diffusivity of the drying material. The higher the thermal diffusivity of the drying material, the greater the peak temperature achieved. The peak temperature of the drying material increases with the increase in the contacting percentage. The higher feeding velocity leads to a faster increase in the temperature of the drying material; however, the peak temperature of the slower feeding velocity is higher than that of the faster one. The heat transfer between the central layer of the drying material and to ambient environment is limited by the thermal diffusivity of the drying material.

Multiphase Flow Characteristics in the Classification Process of a Novel Wide Neck Thickener: Experiment and Simulation.

A novel thickening equipment known as a wide neck thickener (WNT) was designed to solve the problem of depending only on gravity settlement of the thickener. The computational fluid dynamics method with the Reynolds stress and the volume of fluid models and the particle image velocimetry experimental method were both applied to investigate the pressure and velocity variation and turbulent characteristics of the WNT under different parameter settings. The results indicate that experiments and simulations are consistent. Under four parameter settings, the axial and tangential velocities decrease to the minimum and then increase from the wall to the center. Under different feed velocity, cone angle, and spigot diameter settings, turbulent kinetic energy k and intensity I decrease from the cylinder to the cone and from the wall to the center; the max k and I correspond to the area near the inlet followed by the cylinder, and k and I in the cone are the smallest. When the classification overflow outlet (COO) diameter is 200 mm, k and I increase rapidly, the max k and I are transferred from near the inlet to near the cylinder wall at the COO, and the k and I near the wall decrease significantly.

CFD simulation and optimization of an energy-efficient direct contact membrane distillation (DCMD) desalination system

In this paper, the CFD simulation and optimization of an energy-efficient direct contact membrane distillation (DCMD) desalination system in a counter-current flow mode are performed. Two-dimensional modeling was applied and the governing equations for momentum, heat, and mass transfer in the three regions i.e., feed channel, membrane, and permeate channel were solved and corresponding velocity, temperature, concentration fields, and the permeate water flux through the membrane was obtained. A two-step approach was considered to optimize the desalination system through the MD process. First, the model results were validated with the reported experimental data and good agreements were observed. The maximum deviation for the outlet concentration and hot stream outlet temperature with different feed velocities and temperatures was 0.33%. Then, the process was optimized for maximizing the permeate flux. Since the number of parameters was high, the response surface methodology (RSM) was used to find the optimum condition in order to obtain the maximum water flux. It was determined that the highest permeate water flux would be gained at the permeate temperature, the hot feed flow rate, the cold-water flow rate, the length and height of the channels of 35 °C, 20 lit/min, 10.25 lit/min, 20 cm, and 3 cm, respectively. At this optimum condition, a permeate flux of 53.5 kg/m2.h and a TPC of 0.82 are expected.

Comparison of two Specialized Cleft Palate Feeders.

To evaluate feeding efficiency and weight gain in infants with cleft palate fed using 1 of the 2 specialty feeders. Retrospective cohort study. Cleft palate clinic in a tertiary pediatric hospital. Infants with cleft palate (with or without cleft lip) fed using the Medela SpecialNeeds® Feeder (n = 39) or the Dr. Brown's® Specialty Feeding System (n = 16) and who had documented feeding and growth data available from the time of initial assessment in the first month of life and at subsequent follow-up between 2 and 4 months. Feeding velocity (mL/min). Calorie velocity (kcal/min), weight gain, and complications associated with poor feeding. No statistically significant differences in feeding or calorie velocities were identified between infants with cleft palate fed with the Medela SpecialNeeds® feeder and those fed with the Dr. Brown's® feeder. Mean weight z-scores by month did not differ significantly between the 2 bottle groups at the time of initial assessment (P = .84) and follow-up (P = .20). Mean weight z-scores by month for the infants included in this study fell below the 50th percentile. The proportion of infants who developed otitis media, reflux requiring treatment, or who required hospital admission for nasogastric (NG) feeds did not differ significantly between the 2 groups. Despite being adequately powered for the primary outcome, no significant differences were identified between infants fed with the Medela or the Dr. Brown's feeders in terms of feeding velocity, calorie velocity, weight gain, or complications.

A Model-Based Trajectory Planning Method for Robotic Polishing of Complex Surfaces

Off-line programming of the polishing tool trajectory for complex workpieces is challenging due to the nontrivial material removal model and the polishing accuracy requirement. Current tool trajectory planning methods are mainly developed for some simple surfaces but cannot handle the increasingly complicated industrial parts, such as the wheel hubs. This article first develops a numerical contact mechanics model for the point-sampled complex workpieces. The contact pressure distribution and the material removal depths on the workpiece point cloud can be predicted efficiently. A novel high-priority subregion searching algorithm is developed to track the most-worth-polishing workpiece points. By selecting the path pattern as direction-parallel, the path direction, tool dwell times, and the path spacings inside each extracted subregion are optimized to minimize the deviation from the desired material removal depths. The effectiveness of the proposed method is verified by performing disk polishing simulations on workpieces with different shapes. A robotic polishing experiment is also conducted on a wheel hub. Both simulation and experimental results show that reasonable tool trajectories can be generated on the workpiece, and the desired material removal depths can be achieved. Note to Practitioners—In robotic polishing industries, it is crucial to plan the tool trajectory (tool path and feed velocity) to achieve desired material removal depths on the workpiece surface, which means high surface quality. In this article, a model-based tool trajectory planning method for robotic polishing of complex surfaces that are represented by the point cloud form is presented. The advantage of using the point cloud is that workpiece surfaces with varying curvatures and complex features, e.g., grooves and holes, need not be expressed explicitly. The proposed method generates high-priority subregions according to the updated material removal distribution dynamically. In this work, the polishing path pattern is chosen as direction-parallel. Based on an efficient numerical contact mechanics and material removal model, the path locations and the tool dwell times inside each subregion are optimized to minimize the deviation between the actual and the desired material removal depths. When the desired material removal depths are attained in an extracted subregion, the algorithm finds the next high-priority subregion until the whole workpiece is well polished. The trajectory planning method can be integrated into an industrial robot with the force-control module. Future work is to integrate the roughness model into the tool trajectory planning method.

Separation of Copper-Molybdenum Flotation Concentrate by Superconducting High-Gradient Magnetic Separation

Separation of chalcopyrite from molybdenite is currently mainly carried out by flotation, but this process is costly because of the extensive use of inhibitors. This study briefly describes a 7.0T/100CGC low-temperature superconducting magnetic separator and discusses its separation principle as well as the effect of magnetic induction on chalcopyrite separation from molybdenite. A molybdenum (Mo) concentrate assaying 6.00% copper (Cu) and 19.01% Mo was magnetically sorted using a diamond-shaped steel rod medium mesh at a feed concentration of 20% and a pulp flow rate of 5 L/min from a Cu-Mo flotation concentrate with 88% of particles smaller than 23 μm using the separator. A Mo concentrate assaying 0.46% Cu and 16.28% Mo was finally obtained with a roughing (1.3 T)-cleaning (5 T) superconducting magnetic separation process. Similarly, the superconducting magnetic separator was performed to separate a Cu-Mo bulk flotation concentrate, and produced Cu concentrate assaying 19.64% Cu and 0.03% Mo from the bulk concentrate assaying 18.52% Cu and 0.39% Mo with a particle size of less than 0.074 mm. At a magnetic induction of 7 T, a pulp concentration of 20% and a feed velocity of 5 L/min, the grade and recovery of Cu in the magnetic product were 19.64% and 81.59%, respectively, whereas the grade and recovery of Mo in the non-magnetic product were 1.52% and 90.07%, respectively. Superconducting magnetic separation has potential applications for removing Cu from Mo concentrates, and separating Cu and Mo from Cu-Mo bulk flotation concentrates.

Spiral metal tube multi-roller bending springback prediction model based on dynamic deformation enhancement analysis

The spiral metal tube has well stability manufactured by multi-roller bending (MRB) equipment owing to its curvature and torsion characteristics, while the springback is difficult to be alleviated concurrently. The effects of strain rate and relative twisting angle determined by process factors on springback cannot be ignored as well as the material and geometrical characteristics in MRB. In this paper, a novel theoretical model of the springback prediction of the spiral tube is established under the Frenet frame based on Johnson-Cook (JC) model and power hardening model. The concept of dynamic deformation enhancement analysis is proposed to clarify the impact of rate dependence on springback response. Taking the AISI 316L spiral tube as an example, the accuracy of the proposed theoretical model is verified by explicit finite element (FE) analysis and bending experiment. In the deviation analysis, the prediction deviation of the theoretical model is 1.72 %, which is closer to the experiment result than the FE analysis. The springback behavior of the spiral tube considering the variations of feeding velocity, base circle radius, and lead angle in the MRB process is studied. The elastic recovery of the spiral tube is characterized by the increase of the spiral base circle radius and the decrease of the lead angle. The results show that the higher strain rate and relative twisting angle have an enhancement effect on the spiral tube and reduce the elastic recovery in low forming speed MRB process.

Impact of the Polarization Layer on the Hydrodynamics and Mechanical Performance of a Filtering Hydrocyclone Applied to Oily Water Separation

The growing concern with the environment has driven the development of new technologies for the treatment of produced water. In this context, the filtering hydrocyclone appears as an interesting alternative for the treatment of these waters contaminated with oil from the petroleum industry. This research addresses the flow of fluids inside a hydrocyclone equipped with a porous wall (membrane) containing two tangential inlets and two concentric outlets, with the aim of study the impact of the formation of the polarization layer by concentration on the oily water separation process using CFD. Concentration fields and transmembrane pressure, concentration, and permeate flux profiles are presented and analyzed. The results show that the proposed filtering cyclonic separator concentrates the oil in the central region of the equipment, however, for high oil concentrations; the core expands and approaches the porous wall. Furthermore, the increase in the oil volume fraction causes a decline in the permeate flux, and an increase in feed velocity causes a decrease in the polarization layer.

Research on Processing Error of Special Machine Tool for VH-CATT Cylindrical Gear

The variable hyperbolic circular arc tooth trace (VH-CATT) cylindrical gear is a new gear suitable for heavy loads and high speed. The special structure of the gear provides excellent mechanical properties but also increases the processing difficulty. The special machine tool for VH-CATT gear provides a prerequisite for mass production, but the machining accuracy remains to be improved. Therefore, this paper proposes a Kriging model based on the glowworm swarm optimization algorithm of scene understanding (SGSO) to study the relationship between input parameters and output precision. Then, the SGSO algorithm is used to optimize the parameters of the Gaussian mutation function in the Kriging model to improve its fitting accuracy. When solving four groups of tooth profile and tooth direction errors, the key precision index, R2, of SGSO-Kriging all exceed 0.95. Additionally, the feasibility of the model is verified by the residual diagram and the box diagram. The contour diagram and error results show that reducing the feeding velocity, vf, can improve accuracy most efficiently, and the increase of rotational speed, n, is more conducive to the accuracy of the tooth surface than the acceleration of the coolant, vQ. The above research provides an optimization strategy of gear machining accuracy and a theoretical basis for the promotion of the VH-CATT gear.

Modeling the relationship between forward osmosis process parameters and permeate flux

Artificial neural networks (ANN) models are becoming more popular than mathematical and transport-based models due to their high performance and accuracy. Previous literature shows a lack of application of powerful ANN techniques for predicting forward osmosis (FO) performance. In this study, we developed a feedforward network to predict and analyze the permeate flux in the FO process. The ANN model was developed based on a lab-scale experimental database from various published articles. The permeate flux was modeled as a function of membrane-type, membrane orientation, feed and draw solution molarity, feed and draw velocity, molecular weight, feed solution temperature, and draw solution temperature. The influence of foulants on permeate flux has not been considered for developing the ANN model to avoid over-complication of the present work. The adj. R-squared values for train, unseen test and total datasets are 0.99, 0.92, and 0.95, respectively. These values are higher than those found in previously published literature (0.97, 0.85, and 0.82). Moreover, this is the first time that the effect of individual variables on permeate flux has been estimated quantitatively.

Delineation of the diamine monomers effect on the desalination properties of polyamide thin film composite membranes: Experimental and molecular dynamics simulation

The success of membrane desalination technology hinges on the properties of thin film composite (TFC) membrane that is commonly fabricated by interfacial polymerization (IP) of diamine and acyl chloride. The current study aimed to investigate the impact of the length of the alkyl side chain of the diamine monomers on the desalination performance of the TFC membranes. Four diamines (piperazine (PIP), 1-(2-aminoethyl)piperazine (EAP), 1,4-Bis(3-aminoprpyl)piperazine (DAPP), and m-xylylenediamine (XLN)) were used to fabricate four different TFC membranes with trimesoyl chloride (TMC) as a crosslinker. The merits of the TFC membranes were thoroughly characterized and the PIP was found to be advantageous compared to other diamines with different aliphatic alkyl chain lengths. Molecular dynamics simulations showed that PIP TFC membrane has a tight pore diameter of 1.1 nm and polar carboxylic groups within its pores, which makes it strongly hydrophilic reporting a water contact angle of 28°. The salt rejection (%) of the PIP TFC membrane followed the order: MgSO4 (91%) > Na2SO4 (85%) > Na2CO3 (77%) > NaCl (32%). The increase in feed pressure, temperature or velocity had a positive impact on the permeate flux. However, salt rejection deteriorated as the temperature of the feed increased.

Investigation of the induction time and recovery in a flotation column: A kinetic analysis

ABSTRACT The recovery of coal particles in a flotation column was investigated to determine its dependency on the type of frother, particle size, and gas and feed velocities. The kinetics of the cumulative recovery was established. The induction time and flotation rate constant were analyzed based on the recovery, incorporating the stability, attachment, and collision efficiencies of the particles with the bubbles. An inverse relationship between recovery and induction time was observed. Recovery of the particles was noticed to increase with superficial air velocity and frother dose, while it decreased with increasing particle size and feed circulation velocity. The induction time decreases with increasing superficial air velocity and frother dose but increases with increasing particle size and feed circulation velocity. Low induction time and high recovery were observed in the cationic frother. Small particles with low induction time can be captured with ease and have excellent selectivity. A generalized correlation for the induction time was proposed based on experiments under different operating conditions. The presented research will be beneficial in terms of increasing the transport efficiency of flotation systems.

Effect of membrane surface wetting on the performance of direct contact membrane distillation for seawater desalination

Membrane distillation (MD) is a standalone process to generate fresh water and is especially attractive when low-grade waste heat or renewable thermal energy is available. Surface wetting hinders the commercialization of Membrane distillation (MD) technology by deteriorating the permeate quality, thermal efficiency, and transmembrane flux. There is still a lack of understanding on how and to what extent the partially wetted membranes affect the performance of direct contact MD (DCMD) systems. It is of great importance to optimize the operating conditions under such conditions. The DCMD performance was addressed in the literature by considering non-wetted or fully wetted membranes. This study for the first time proposes a computational model to investigate the effect of membrane surface wetting ratio (R = L wet /L total ) on the transmembrane (J) and thermal efficiency (η) of a DCMD module. Parametric and sensitivity analyses were performed to display the effect of system parameters (feed temperature, feed velocity, permeate temperature, permeate velocity, membrane thickness, and membrane surface wetting ratio) on the Key Performance Indicators (KPIs) of the DCMD module. The obtained results indicate that the permeate side temperature has more effect (more than twice) on KPIs in wetted membranes (∼30% and ∼15% rise in J and η) compared to the non-wetted ones (∼15% and ∼5% enhancement in J and η), and the negative effect of membrane surface wetting could be minimized by adjusting the permeate side operational conditions. The effect of membrane wetting ratio on the performance of the DCMD module in thin membranes (≤0.2 mm) and thick membranes (≥0.25 mm) strongly depends on the permeate and feed temperatures. The parametric and sensitivity analysis performed in this study will be beneficial to optimizing the operational conditions of MD systems for maximizing their performance and could serve as valuable guidelines in the development of efficient water desalination systems. • A numerical model was developed to investigate the performance of the partially wetted DCMD module. • The effect of surface wetting ratio (R = L wet /L total ) was investigated using a parametric study. • A sensitivity analysis was performed to quantify the relative impact of operating conditions. • The effect of permeate properties is more dominant for surface wetted membranes. • Permeate and feed temperatures dramatically alter the R ratio effect in thin and thick membranes, respectively.

Optimization and active control of internal gearing power honing process parameters for better gear precision

Abstract. Optimization and active control of internal gearing power honing (IGPH) process parameters for excellent and stable gear precision were carried out using the engagement theory of a conjugate curved face, the Box–Behnken design of experiments method, and the artificial immune clone selection algorithm (AICSA). Optimization and active control were carried out in four stages. In the first stage, the second-order models of tooth profile deviations were developed considering the nonlinear influence of IGPH process parameters on tooth profile deviations based on the Box–Behnken design. In the second stage, a method for solving the multi-objective optimization of the IGPH process was presented based on building the synthetic tooth profile deviation model, which considered the different weighting factors of different tooth profile deviation indexes. In the third stage, excellent gear precision was obtained by importing the ranges of synthetic tooth profile deviation and parameters into the AICSA. In the fourth stage, based on the optimized process parameters, the active control of IGPH process parameters was realized based on the constant cutting speed on the fixed position of the gear tooth surface. The total gear profile error reached a minimum value at the optimal parameters of 1270.4 rpm for spindle speed, 60 mm min−1 for axis feed velocity, 2.4 µm per oscillation for radial feed velocity, and 2.4 spark-out times. The gear accuracy test results show that the total gear profile error value from the above active control method is more stable and lower than that without active control, indicating that the proposed method is effective.

Influence of Oil Status on Membrane-Based Gas-Oil Separation in DGA.

Gas–oil separation by membrane stands for a promising technique in dissolved gas analysis (DGA). Since the accuracy of DGA relies on the results of gas–oil separation to a great extent, it is necessary to study the influence factor of membrane for better performance. Although plentiful studies have been conducted aiming at membrane modification to obtain better separation performance, it cannot be ignored that the conditions of oil also affect the performance of membrane much. In this work, a photoacoustic spectroscopy-based sensor for DGA, which employed membrane for gas–oil separation, was established first. By detecting the photoacoustic signal, the performance of membrane could be evaluated. Furthermore, the influences of feed velocity and pressure have on the performance of membrane were analyzed. Both simulation and experiment were employed in this work to evaluate the influences by collecting the equilibrium time of membrane under different conditions. As a result, the simulation and experiment agreed with each other well. Moreover, it was reasonable to draw the conclusion that the equilibrium time was evidently reduced with the raise of feed velocity but remained with a minimum change when pressure changed. The conclusion may serve as a reference for the application of membrane in optical sensor and DGA.

Pulsation curves strengthen the high gradient magnetic separation process: Experimental study and simulation explanation

The pulsating slurry high gradient magnetic separator (PHGMS) has been widely used for the separation of feebly magnetic materials. As the main competing force, pulsating slurry effectively overcomes matrix blockage and affects the buildup behavior of particles. At present, the used pulse shape in PHGMS constitutes a sinusoidal harmonic vertical motion in which the duration and intensity of the impulsion and suction strokes are similar. However, other pulsation profiles, such as, trapezoidal shape and saw-tooth shape pulses, can also be obtained depending on the stratification mechanism. There is little literature to focus on how pulse shape influences the performance of PHGMS. The change of curve could be a method worth exploring to improve the separation. In this paper, the asymmetry pulsating curves are obtained by switching the velocity of the step motor during one cycle. Then, the single-wire experiments, single-wire 2D numerical simulation and multi-wires experiments are presented to indicate the effect of different pulse shapes. In single-wire experiments, compared with the traditional sinusoidal harmonic curve, the asymmetry pulsating curves have a higher grade, finer particle buildup, but lower accumulation volume. The curves of the rapid downward stroke and slow upward stroke are better than the inverse movement curve in asymmetry pulsation. The results of separating the up and downstream accumulations on the magnetized wire and numerical simulation reveal that these effects can be attributed to the direction of net force and vortex strengthening. The trajectory simulation of multi-component obtains a similar result with single-wire experiments to confirm the superiority of rapid downward stroke and slow upward stroke in selectivity. However, in multi-wires experiments, due to the matrix blockage the curves of rapid upward stroke and slow upward stroke show the greater potential advantages in both grade and weight compared with other curves at condition of high feed velocity.

Dynamic behavior of CO2 adsorption from CH4 mixture in a packed bed of SAPO-34 by CFD-based modeling

Abstract In this work, a dynamic non-isothermal adsorption process of CH4 and CO2 in a fixed bed of SAPO-34 particles was modeled by coupled DEM-CFD. This Euler–Lagrange method gives access to specification of each adsorbent pellet including location, temperature and concentrations, and facilitates study of phenomena like adsorption. Transport phenomena including heat and mass transfer in fluid and between solid and gas were taken into account. Eventually the model was validated by experimental results of breakthrough curve. Especially near wall channeling effect and the role of inlet feed velocity on the bed efficiency were addressed in this work. Local and bulk porosity values calculated using DEM model showed an acceptable agreement with previous empirical equations. Results indicated that this coupled method can be applied as a promising tool to study the mass transfer zone and efficiency of the adsorption process. The results revealed that as the feed continues to flow into the column, the lower layers of the adsorbent particles become practically saturated and then the mass transfer zone starts moving upward to a region of fresher adsorbent in the column. Also, the results showed that, at a low inlet velocity with a low Peclet number (Pe = 0.195), channeling effect is reduced and the diffusion mechanism controls the mass transfer. However, HETP enhances with increase in the feed gas velocity (Pe = 2.25) as well as increase in deviation from plug flow regime, and consequently the adsorption efficiency decreases. HETP decreases drastically at the beginning with increase in interstitial velocity. Increase in the interstitial velocity beyond a particular value of 0.5 cm s−1 leads to increase in the HETP value. This trend and presence of a minimum in this graph were explained based on Van Deemter concept.

Osmotic Membrane Distillation Crystallization of NaHCO3

A new crystallization process for sodium bicarbonate (NaHCO3) was studied, proposing the use of osmotic membrane distillation crystallization. Crystallization takes place due to the saturation of the feed solution after water evaporation on the feed side, permeating through the membrane pores to the osmotic side. The process operational parameters, i.e., feed and osmotic velocities, feed concentration, and temperature were studied to determine the optimal operating conditions. Regarding the feed and osmotic velocities, values of 0.038 and 0.0101 m/s, respectively, showed the highest transmembrane flux, i.e., 4.4 × 10−8 m3/m2·s. Moreover, study of the temperature variation illustrated that higher temperatures have a positive effect on the size and purity of the obtained crystals. The purity of the crystals obtained varied from 96.4 to 100% In addition, the flux changed from 2 × 10−8 to 7 × 10−8 m3/m2·s with an increase in temperature from 15 to 40 °C. However, due to heat exchange between the feed and the osmotic solutions, the energy loss in osmotic membrane distillation crystallization is higher at higher temperatures.

Model predictive force control in milling based on an ensemble Kalman filter

Process force determines productivity, quality, and safety in milling. Current approaches of process design often focus on a priori optimization. In order to enable online optimization, the establishment of active force controllers is required. Due to fast-changing engagement conditions of the tool in conjunction with the slower machine dynamics, classic control is not suited. A promising approach is the application of model predictive control (MPC) for force control, which is proposed in this contribution. The model predictive force controller (MPFC) explicitly takes into account a model to predict the immediate future. It consists of a model of the machine tool and a separate model of the process. The process model describes the relation between feed velocity of the tool, force, and geometric properties of the tool, such as the radial deviation, and of the tool/workpiece engagement. The feedback loop of the controller is closed by an online identification of the process model to account changes in the material properties or of the tool wear state. For this identification an ensemble Kalman filter (EnKF) is applied. The MPFC solves an optimization problem on the future behavior in each sampling step to determine the optimal controller output enabling high dynamic control. The proposed control system is validated experimentally and compared with a conventionally designed process with constant feed. It can be shown that the manufacturing time is reduced by 50%. The system enables a paradigm shift in the design of milling processes operating the manufacturing process at its technological limit.