Titanium alloys have great potential in ultra-precision situations due to the excellent properties, such as high corrosion resistance, high specific-strength and high biocompatibility. However, the application of titanium alloys in ultra-precision field is limited by the poor machinability. There are difficulties in obtaining the optical surface. In this study, the possibility for obtaining optically graded surfaces of titanium alloys by ultra-precision polishing was investigated. Before the ultra-precision polishing, ultra-precision turning with a single point diamond tool was used to get all sample surfaces. But, titanium alloy is difficult to obtain good surface quality by ultra-precision diamond turning. The samples results confirmed that most of the surface roughness values are higher than 30 nm. In order to explore the polishing process, a large number of ultra-precision polishing experiments were conducted. In addition, the effects of different ultra-precision polishing parameters on the surface profiles of titanium alloy Ti6Al4V were investigated in depth. The results show that the average values of surface roughness of titanium alloy parts with ultra-precision turning can be further reduced by 70% or so by ultra-precision polishing. Using a reasonable combination of high spindle speed and large cutting depth, the value of surface roughness can even be lower than 2 nm.
The Ti-6Al-4V titanium alloy is a kind of light alloy material with high specific strength, corrosion resistance and heat resistance. Because of its excellent performance, it has become an important material in aerospace industry. However, this kind of alloy has very poor machinability, and rapid tool wear is a very serious problem in titanium alloy processing. At present, it is difficult to guarantee the ultra-precision machining quality of titanium alloy materials, which limits its application in high-tech fields. In order to solve this problem, the influence of cutting speed on ultra-precision cutting process of titanium alloy was analyzed comprehensively. and it was found that better surface quality could be obtained at lower cutting speed. In order to study the influence of cutting speed in ultra-precision cutting of titanium alloys, cutting experiments have been carried out. Additionally, a finite element model was established to analyze the ultra-precision cutting process. Also, the constitutive model, damage model, friction model, and heat transfer in the modeling process were discussed. The chip morphology, cutting temperature, cutting force, and surface morphology under different cutting velocities are analyzed by simulation. Then, the simulation results were compared with the experimental results. The findings show that cutting speed has great influence on the ultra-precision turning of the Ti-6Al-4V alloy and the surface roughness obtained by ultra-precision cutting of titanium alloy can be lower than 20 nm at a lower cutting speed.
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