Speed Milling Research Articles

Controlling harmful milling vibration for robotic milling system based on the optimization of milling posture and spindle speed

Harmful machining vibration including milling chatter and resonance are easily generated during robotic milling process, and it seriously restrict the machining ability of the robot. To address this problem, a harmful machining vibration-controlled method based on the combined optimization of milling posture and spindle speed is proposed for robotic milling system in this paper. With this context, firstly, the robot stiffness model is established based on the theory of the multi-body with small-deformation, and the stiffness ellipsoid at the tool cutting point is used to optimize the milling posture, so that the structure stiffness of the robot can be enhanced; Then, the robot chatter stability model is constructed considering the modal coupling effect, and the spindle speed is optimized to restrain the milling chatter and resonance. Finally, with the optimized milling posture and spindle speed, the milling process is planned and performed with a Staubli TX-200 robot, and two experiments for workpiece with steel and aluminum are implemented to verify the proposed method. The experiment results demonstrate that the comprehensive optimization of milling posture and spindle speed can efficiently control the harmful machining vibration for the robotic milling system, thus, the machining quality of the workpiece can be improved.

Study on the friction and wear properties of 7075-T6 aluminum alloy enhanced by milling and ultrasonic impact treatment

This study investigates the effects of milling parameters on the surface friction behavior of 7075-T6 aluminum alloy subjected to ultrasonic impact treatment. A three-dimensional milling and friction-wear model was developed using ABAQUS finite element analysis, examining the influence of milling speed, depth, and feed rate on the coefficient of friction, wear volume, and surface morphology through single-factor experiments. Results indicate that milling parameters affect the friction coefficient in the following order: Vc > f > ap. Specifically, increasing milling speed from 35 m/min to 59 m/min raises the average friction coefficient from 0.305 to 0.387, a 26.88 % increase. At a milling speed of 83 m/min, the friction coefficient and wear volume reach their lowest values of 0.305 and 0.977 mm³, respectively. The wear volume decreases with increasing milling speed and feed rate, while milling depth has a minor effect. The most significant reduction in wear volume, from 5.76 mm³ to 0.977 mm³ (an 83.04 % decrease), occurs as milling speed increases from 35 m/min to 83 m/min. Maximum longitudinal slip during the reciprocating motion primarily occurs at the ends, with both positive and negative peak offsets. Surface damage from 304 stainless steel balls against the 7075-T6 alloy involves adhesive and abrasive wear. At a milling depth of 35 μm, friction-induced compounds in the transfer film mainly consist of Al, C, Fe, Zn, Mg, and Cr.

The influence of ball milling conditions on the powder characteristics and sintering densification of Mo[sbnd]Cu alloy

Mechanical alloying was utilized to produce Mo-30Cu(wt%) composite powder. The effects of milling conditions on the powder characteristics and sintering densification were investigated. The morphological evolution during the mechanical alloying process can be categorized into four stages: 1-individual Mo and Cu particles, 2-coexistence of Mo particles and blocky MoCu composite particles, 3-coarse irregular composite particles, and 4-refined near-spherical composite particles or lamellar MoCu composite particles, depending on whether process control agent (PCA) is added. The mechanical alloying degree of the MoCu composite powder was deepened gradually from stage 1 to 4, which is influenced by the ball milling parameters. As the milling speed and milling time increase, the lattice strain and the alloying degree of the MoCu composite powders increase while the grain size of molybdenum particles decreases, which is conducive to accelerating the sintering density. Among these ball milling parameters, an elevated milling speed notably accelerates the mechanical alloying process and the sintering density. Under the milling speed of 600 r/min, ball to powder ratio (BPR) of 10:1, and milling time of 4 h, the grain size, lattice strain, and average particle diameter of the composite powder were measured to be 48.4 nm, 0.247 %, and 21.04 μm, respectively, with the particle morphology being nearly spherical. The sintered density of the MoCu composite reached 98.1 %, larger than the other composites.

Mass finishing of additively manufactured AISI 316L using pecan nutshells as sustainable abrasive media

Abrasive processes represent the main methods for obtaining high-quality surface finish in metal parts. As one main characteristic, these processes have a relatively high consumption of energy per material volume removed, as well as many inputs, such as abrasive tools and equipment, and, consequently, a high associated environmental impact. Additive manufacturing is becoming a competitive method to produce customized parts, but the surface finish is often not good enough for the application, and post-processing is needed. In this work, a mass finishing process using a planetary mill with abrasive media made of sustainable materials (pecan nutshells) was used on AISI 316L stainless steel samples manufactured by selective laser melting (SLM). The main goal was to perform a multicriteria analysis of the sample surface before and after post-processing. Through the analysis, it could be observed that the nutshell abrasive media has results close to those of traditional ceramic media. The increase in the rotation speed of the planetary mill, increase of finishing time, and use of abrasive pastes can further increase the effectiveness of the process.

Zero-valent iron on graphite-cellulose biochar catalysts for the Fenton degradation of tetracycline from water

Tetracycline (TC), an antibiotic widely used in the treatment of animal and human diseases and promotion of animal growth. However, its uncontrolled discharge to water sources can also cause the promotion of antibiotic resistant bacteria and genes. In this study, graphite and cellulose were used as raw materials to construct a graphite-biochar (G-BC) by carbothermal reactions. This graphite-biochar was subsequently mixed with ZVI with various mass ratios by ball milling to produce graphite-biochars supported ZVI (ZVI/G-BC) catalysts, further used in the heterogeneous Fenton degradation of tetracycline. The materials were fully characterized by different techniques. The removal of TC by BC, G-BC and ZVI/G-BC was tested under different reaction conditions. The best synthesis conditions were achieved at a heating temperature of 700 °C, a graphite content of 20 %, a ball milling speed of 500 rpm, a ball milling time of 5 h, as well as a G-BC and ZVI mass ratio of 1:3. Graphite improves the conductivity and micropore area of the material, which enhances the removal of TC by ZVI/G-BC catalysts in Fenton-like reactions. TC was first oxidized to intermediate products and then further mineralized to CO2 and H2O. The best TC removal performance was obtained with a catalyst dosage of 1.1 g·L1, a hydrogen peroxide concentration of 140 mM and an initial pH value of 3. The reaction data fitted properly a pseudo first-order kinetic equation. TC removal as high as 91 % was achieved even in the 3rd round of reuse. This study reports a novel ZVI material with high conductivity and good TC removal performance.

Research on the thermal energy environment and process parameters of milling process in ceramic art design

In ceramic art design, milling technology is the key processing technology, which directly affects the quality and artistic expression of ceramic products. However, the thermal energy environment generated in the milling process has a significant impact on the material characteristics and machining results. This study aims to explore the influence of the thermal energy environment on the ceramic art design during the milling process, optimize the process parameters, and improve the processing efficiency and product quality. Experiments with different milling speed, feed rate and cutting depth were designed to compare and analyze the change of thermal environment by combining experiment and simulation. The influence of thermal energy on ceramic machining quality was evaluated by monitoring the temperature distribution in the cutting process with thermal imaging technology and combining with the experimental data of material properties. The experimental results show that the temperature increase in milling process is closely related to the cutting speed and feed rate, and proper control of the thermal energy environment can significantly reduce the crack generation rate and improve the surface finish of ceramic materials. The optimized process parameters make the temperature control in the milling process within the ideal range, thus realizing the processing of high quality ceramic products. Through reasonable optimization of process parameters, the heat energy in the processing process can be effectively controlled, which helps to improve the overall quality and artistic value of ceramic works.

Preparation of M-type barium ferrite submicron absorbing powder by one-step high-temperature ball milling and its particle structure regulation

This study investigates a simple and rapid process for directly preparing M-type barium ferrite using high-temperature ball milling. By adjusting the rotation speed of the high-temperature ball milling, the morphology and size of the powder can be altered to regulate its electromagnetic properties, aiming for an overall good absorbing effect. The powder’s morphology, agglomeration properties, elemental valence states, and electromagnetic parameters were characterized using SEM, BET, XPS, EDS, and VNA. The results show that as the milling speed increases, the particle size of the M-type barium ferrite decreases, transitioning from the typical hexagonal flake particles to spherical block particles, forming a porous loose structure with richer dielectric loss mechanisms and enhanced electromagnetic wave loss capacity. Electromagnetic loss performance analysis indicates that at a milling speed of 50 rpm, the powder achieves the best electromagnetic loss of −61.16 dB at a matching thickness of 8.77 mm and a microwave absorption bandwidth of 4.1 GHz.

Effect of ball milling activation on CO2 mineralization performance in fly ash and fire resistance capabilities of mineralized product

Coal-fired power generation has always been a major energy supply source globally. However, a large amount of CO2 is emitted with the combustion of coal resources, and fly ash, a by-product of coal combustion, is also accumulated in large quantities. The application of CO2 mineralization in fly ash can not only reduce CO2 emission but also effectively manage industrial waste, thereby promoting environmental sustainability. This paper used the mechanical ball milling method to activate fly ash and investigated the effects of ball milling time and speed on the CO2 sequestration in fly ash. At 30 min ball milling time and 400 r/min ball milling speed, the modified fly ash achieves a good CO2 sequestration capacity of 81.70 gCO2/kgFA. Compared with raw fly ash, the CO2 consumption of treated fly ash is higher at 75.41 mmol/mL. The specific surface area and pore volume of treated fly ash are larger at 1.57 m2/g and 4.33 cm3/kg respectively, which is beneficial for enhancing mass transfer capacity and the carbonation effect. As the ratio of mineralized product/coal increases from 0.5 to 4, the crossing-point temperature increases from 157.20 °C to 165.15 °C. Based on the experimental results, the paper discussed the mechanism of ball milling activation to enhance the carbonation effect of fly ash. This study provides theoretical references for the environmentally friendly utilization of fly ash.

Investigation of the effect of residual waviness formed by rail profile milling of reshaped surface on wheel-rail contact stresses and low cyclic fatigue

The rail profile milling process allows considerable thickness to be removed in a single pass. However, the residual waviness formation law after milling and its subsequent effect on rail performance remains uncertain. In this paper, the wavelength and wave height of the residual waviness are identified as the key characteristics. The relationship between milling speed and residual waviness is determined, and a numerical model of the residual waviness formed on the surface after milling is established based on the commonly used three milling speeds of 300, 600, and 1000 m/h, and its accuracy is verified using the parameters of the residual waviness detected by the milling experiments. A three-dimensional finite element analysis model of wheel-rail contact was employed to analyze the contact stresses and low fatigue cycles at a wheel load of 11.5 tons with no residual waviness on the rail profile surface and with three types of residual waviness, respectively. The results show that the residual waviness changes the wheel-rail contact position and the morphology of the contact area, reduces the maximum contact stress and increases the strain fatigue cycles. The application of elevated milling speeds reduces the wheel-rail contact stresses after milling, thereby increasing the low fatigue cycles.

Optimization of Phenolic-Enriched Extracts from Olive Leaves via Ball Milling-Assisted Extraction Using Response Surface Methodology.

This study aims to extract phenolic-enriched compounds, specifically oleuropein, luteoloside, and hydroxytyrosol, from olive leaves using ball milling-assisted extraction (BMAE). Response surface methodology (RSM) and the Box-Behnken design (BBD) were used to evaluate the effects of the temperature, solvent-to-solid ratio, and milling speed on extraction recovery. The contents of the extract were determined by ultra-high-performance liquid chromatography-mass spectrometry (UPLC-MS) and converted to recoveries to evaluate the extraction efficiency. The optimal extraction conditions for oleuropein, luteoloside, and hydroxytyrosol were identified. Oleuropein had a recovery of 79.0% ± 0.9% at a temperature of 56.4 °C, a solvent-to-solid ratio of 39.1 mL/g, and a milling speed of 429 rpm. Luteoloside's recovery was 74.6% ± 1.2% at 58.4 °C, 31.3 mL/g, and 328 rpm. Hydroxytyrosol achieved 43.1% ± 1.3% recovery at 51.5 °C, 32.7 mL/g, and 317 rpm. The reason for the high recoveries might be that high energy ball milling could reduce the sample size further, breaking down the cell walls of olive leaves, to enhance the mass transfer of these components from the cell to solvent. BMAE is displayed to be an efficient approach to extracting oleuropein, luteoloside, and hydroxytyrosol from olive leaves, which is easy to extend to industrial production.

Effect of Grinding Conditions on Clinker Grinding Efficiency: Ball Size, Mill Rotation Speed, and Feed Rate

The production of cement, an essential material in civil engineering, requires a substantial energy input, with a significant portion of this energy consumed during the grinding stage. This study addresses the gap in the literature concerning the collective impact of key parameters, including ball size, feed rate, and mill speed, on grinding efficiency. Nine spherical balls, ranging from 15–65 mm, were utilized in six distinct distributions, alongside varying feed rates and mill speeds. ANOVA, Taguchi, and regression analyses were employed to explore their influence on grinding efficiency and cement properties. The findings revealed that ball size variation significantly affects grinding performance, with smaller diameter balls yielding higher efficiency due to increased abrasion and fine formation. Conversely, elevating mill speed generally diminishes grinding efficiency, particularly at speeds approaching 90% of the critical speed, impacting ball shoulder and foot angles. Moreover, increasing the feed rate affects the grinding performance differently based on ball distribution, with finer distributions experiencing adverse effects. Signal-to-noise ratios facilitated determining the optimal control factor levels to minimize energy consumption. Quadratic regression models exhibited strong predictive capabilities for energy consumption in grinding. Ultimately, the optimal grinding performance was achieved with Bond-type ball distribution No. 6, considering ball size, mill speed, and feed-rate interactions, albeit with considerations regarding grinding time and energy efficiency.

The Influence of High-Energy Milling on the Phase Formation, Structural, and Photoluminescent Properties of CaWO4 Nanoparticles.

CaWO4 nanoparticles were obtained by facile mechanochemical synthesis at room temperature, applying two different milling speeds. Additionally, a solid-state reaction was employed to assess the phase composition, structural, and optical characteristics of CaWO4. The samples were analyzed by X-ray diffraction (XRD), transition electron microscopy (TEM), and Raman, infrared (IR), ultraviolet-visible (UV-Vis) reflectance, and photoluminescence (PL) spectroscopies. The phase formation of CaWO4 was achieved after 1 and 5 h of applied milling speeds of 850 and 500 rpm, respectively. CaWO4 was also obtained after heat treatment at 900 °C for 12 h. TEM and X-ray analyses were used to calculate the average crystallite and grain size. The Raman and infrared spectroscopies revealed the main vibrations of the WO4 groups and indicated that more distorted structural units were formed when the compound was synthesized by the solid-state method. The calculated value of the optical band gap of CaWO4 significantly increased from 2.67 eV to 4.53 eV at lower and higher milling speeds, respectively. The determined optical band gap of CaWO4, prepared by a solid-state reaction, was 5.36 eV. Blue emission at 425 (422) nm was observed for all samples under an excitation wavelength of 230 nm. CaWO4 synthesized by the solid-state method had the highest emission intensity. It was established that the intensity of the PL peak depended on two factors: the morphology of the particles and the crystallite sizes. The calculated color coordinates of the CaWO4 samples were located in the blue region of the CIE diagram. This work demonstrates that materials with optical properties can be obtained simply and affordably using the mechanochemical method.

Effect of mechanochemical activation parameters on vanadium recovery from vanadium-bearing steel slag: Critical speed derivation for wet-ball milling

The existing equations in the literature for a mechanochemical activation (MA) critical speed proved that only the ball size, volumetric filling ratio, and the vial/bowl diameter influence the milling speed, thus these equations do not account for all other crucial parameters and the critical speed is constant for all the mechanochemical process parameters for every ball size, quantity powder and number of balls considered. Milling speed is one of the vital process parameters, thus this present work derived a novel equation that accounts for the influence of ball size, the ball-to-powder/slurry weight ratio (BPR/BSR), the mass of the mineral powder, the chemical solution, the inner diameter of the vail and the liquid-to-solid ratio (L:S). MA is very beneficial to the hydrometallurgical process and these parameters are key for an enhanced recovery of the desired metals from the mineral in question. The powder and the chemical solution are related by the liquid-to-solid ratio considered in the activation process, thus as the BPR increases for the ball sizes considered, the critical speed increases drastically. Also, the effect of ball size, milling time, and speed on the recovery efficiency of vanadium from vanadium-bearing steel slag (VBSS) was investigated. The VBSS powder was Na2CO3(aq)-milled with balls of varying size at different milling speeds and ignition/milling times. A mechanochemical activation leaching experiment was carried out for 10g VBSS; at a milling speed of 140 rpm, BPR 7.8/BSR 1.02, ball diameter 10 mm, L:S ratio 5:1, temperature 90 °C, and 30-min ignition time, the vanadium recovery efficiency of above 80 % was achieved. For every predetermined mass of VBSS powder and L:S ratio of the chemical solution concentration; the BPR/BSR and the size of the ball determine the critical speeds which in turn influence the leachability of the vanadium.

Coercivity enhancement of sintered NdFeB magnets by powder Refinement, lubricant increment and Hydrogen-Containing sintering manufacturing

This study investigates powder refinement, lubricant increment, and hydrogen-containing sintering procedures to develop high coercivity in NdFeB magnets. To improve the intrinsic coercivity iHc of sintered NdFeB magnets, it is proposed to control the average particle size and distribution of the magnetic powder by increasing the classification wheel speed of the jet mill during the jet milling process. Additionally, the incremental addition of lubricant is carried out in the additive mixing stage after the magnetic powder is refined. Through the increase of lubricant, the amount of lubricant is enough to completely cover the surface of the powder; hence, the alignment of the powder in the magnetic field forming process is improved, thereby increasing the maximum magnetic energy product (BH)max of the magnet. However, the magnetic properties of the magnet are improved through the refinement of the powder and the increase of the lubricant, but it also leads to the residue of impurities inside the magnet, which actually deteriorates the iHc. Different from the traditional process, this study moved the dehydrogenation procedure to the sintering process, thus reducing the residue of impurities inside the magnet, which is beneficial to the improvement of the magnetic properties of the magnet. Herein, we report a new commercial-scale process (100 kg batches) integrating all the above-modified procedures that reached the best experimental results of iHc = 20.79 kOe, (BH)max = 44.46 MGOe and BHH = 65.25 (i.e., BHH= iHc + (BH)max). The iHc, (BH)max, and BHH of the NdFeB magnet obtained by the new process proposed in this study are 16.47 %, 0.33 %, and 5 % higher than the traditional process, respectively. As a result, iHc has been greatly improved, making NdFeB magnets more conducive to meeting a wide variety of end-user applications, including high-coercivity (>20 kOe) sintered magnets suitable for equipment operating in high-temperature environments.

Preparation of Humic Acid from Weathered Coal by Mechanical Energy Activation and Its Properties

Humic acid (HA) is rich in functional groups with high activity, which can effectively improve the soil environment. The large reserves of weathered coal in China provide sufficient raw material guarantee for HA extraction and utilization. At present, the activation side of weathered coal is still the main technical difficulty that restricts HA extraction. In this study, the weathered coal from Inner Mongolia was used as the raw material, and the mechanical energy was used to activate the weathered coal through a planetary ball mill, which improved the extraction rate of HA and optimized the molecular structure and composition of HA. The effects of four parameters, namely, ball material ratio, ball milling time, ball milling speed, and ball size, on the free HA content of weathered coal were investigated, the HA was extracted by alkaline extraction method, and the activated weathered coal and the extracted HA were characterized. The results showed that a ball material ratio of 9:1, a ball milling speed of 200 r/min, a ball milling time of 200 min, a milling ball size of Ф5:Ф10:Ф15 = 48:42:45 and 56:42:37 are the optimal parameters for the mechanical energy activation, and the HA extraction rate of activated weathered coal under these conditions reached 82.3%, which was 15% higher than that of the unactivated one. Moreover, the aroma of the ball-milled weathered coal increased, the content of oxygenated functional groups increased, and the molecular weight and aroma of HA increased. This provides scientific theoretical guidance for the preparation of HA with high aromaticity and large molecular weight from weathered coal.

Optimization of Slugging and Compression Process for Bicalutamide Tablets

The critical nature of pharmaceutical dosage forms necessitates the optimization of manufacturing process variables to achieve the desired product quality. In this study, slugging (Dry granulation) was selected as an appropriate granulation method to mitigate poor flow properties in the final bicalutamide blend. The chosen process variables include slug hardness, mill screen size, and mill speed. A 23-factorial design was employed to investigate these variables. Process parameters were reproducible, with minimal impact on tablet properties, even when roller speeds varied. Response surface models effectively examine the relationship between response variables and quantitative parameters. The input and process variables for the compression process were predetermined based on the desired quality attributes of bicalutamide tablets. Notably, the p-value for the slugging process was not more than 0.05, indicating their insignificance in tablet content uniformity. Product quality attributes affected by the compression process step include content uniformity, disintegration time, and dissolution. The optimal hardness range was found to be 2.0 to 7.0 kp.

Advances in granular flow modeling: GPU-based multi-sphere DEM approach and tumbling mill dynamics

Modeling irregular-shaped particulate flow systems poses challenges, especially in mineral processing where accurate representation of particle shape is crucial for capturing macroscopic behavior. The multi-sphere approach, employing DEM, addresses this by approximating particles as overlapping spheres within GPU computing. This study validates particle flow dynamics using literature-based data, showcasing the model’s fidelity and GPU advantages. However, calibration and shape approximation limitations require careful consideration. A quaternion-based orientation method enhances DEM and validates experimental data from packing, hoppers, and tumbling mills. Simulations reveal how particle shape influences granular dynamics, affecting lift-off tendencies, responses to lifter face angles, and power draw trends with mill speed changes. Cubical and spherical particles exhibit orderly packing behavior, contrasting with irregular shapes. This investigation underscores the significant role of particle shape in granular dynamics and its implications for industrial processes.

Research on an Accurate Simulation Modeling and Charge Motion Quantitative Evaluation Method for Ball Mill in Confined Space

A ball mill is a type of complex grinding device. Having knowledge of its charge-load behavior is key to determining the operating conditions that provide the optimum mill throughput. An elaborate description of the charge movement inside the ball mill is essential. This study focuses on a laboratory-scale ball mill and utilizes a discrete element simulation model to investigate the impact of mill speed and ball filling on charge-load behavior. Initially, the EDEM 2.7 (Engineering Discrete Element Method) software contact parameters were calibrated through heap-angle experiments. Subsequently, four charge-motion characteristic parameters were defined and analyzed based on Powell’s theory to understand the variations in charge-load behavior. This research proposes a theoretical calculation model for predicting power in a ball mill, highlighting the significance of the CoC (Center of Circulation) and CoM (Center of Mass) in reflecting changes in charge-load behavior. The theoretical model for mill-power prediction is effective and aligns well with the EDEM simulation and experimental results, providing valuable insights for optimizing large-scale ball mill structures and controlling charge motion during production.

Effect of Angle of Incident on Taper Angle in Femtosecond Laser Machining for Fabrication of Cross Section Analysis Specimen

Focused ion beam (FIB) technology is one of the most widely used methods for fabricating crosssectional analysis specimens because of its high precision and characteristics that minimize the occurrence of defects. Demand for large cross-sectional area analysis is increasing to improve product reliability in various industries, but is limited by the low milling speed of FIB. Other potential techniques such as Ar ion milling and plasma FIB have been adopted, but low milling speed for large areas still remains a problem. A promising solution to this issue involves laser machining prior to FIB milling. In laser machining a laser beam is irradiated to remove materials from the target. This technique can provide several orders of magnitude higher material removal rate than FIB, however, tapering of the machined surface and laser induced damage can occur. Removing these defects leads to increased FIB milling time. In this study, the laser parameters including angle of incident (AOI) were optimized to achieve a vertical like sidewall and minimize laser induced defects. Before applying AOI, laser machining parameters were optimized to reduce the angle of the machined sidewall. The taper angle of 2.5° was fabricated using the optimized parameters and application of AOI. Raman spectroscopy, SEM, and EDS analysis were used to measure not only the geometry of the laser machined sidewalls, but laser induced residual stress and defects. These results were then used to calculate the volume of FIB milling required to remove the laser induced damages and achieve vertical sidewalls. The application of AOI can significantly reduce the processing time in the FIB milling compared to the processing time when AOI is not applied.

Wet mechanochemical surface modification of calcite employing an integration of conventional design and analytical hierarchy process

The demand for ultra-fine mineral powders from various industries requires the applications of wet grinding and surface modification. In this study, wet mechanochemical surface modification of micronized calcite (d50 = 4.92 μm) with stearic acid [CH3(CH2)16COOH] was carried out in a planetary ball mill. The seven parameters were specified: ball filling ratio (%), ball size distribution ratio (10 and 15 mm, %), micronized calcite filling ratio (%), pulp solid ratio (wt%), mill speed (rpm), stearic acid dosage (% of micronized calcite) and modification time (min). Then, these parameters were optimized using a conventional experimental design when maximizing the active ratio (%) as a significant value for coated calcite. Besides, the analytical hierarchy process was applied to observe the importance of each parameter. Stearic acid dosage, mill speed, and micronized calcite filling ratio are the top three parameters affecting the active ratio. Next, size distribution, XRF, XRD, SEM, FTIR, TGA-DTA, contact angle, and whiteness measurements were performed on the micronized calcite (MC) and coated micronized calcite (CMC) samples. The final CMC product had a 99.90% active ratio, 2.49 μm mean (d50) particle size, and 101.66o contact angle. Finally, CMC obtained by the surface modification can be used as a filler mineral.