Drilling High Precision Holes in Ti6Al4V Using Rotary Ultrasonic Machining and Uncertainties Underlying Cutting Force, Tool Wear, and Production Inaccuracies

Abstract

Ti6Al4V alloys are difficult-to-cut materials that have extensive applications in the automotive and aerospace industry. A great deal of effort has been made to develop and improve the machining operations of Ti6Al4V alloys. This paper presents an experimental study that systematically analyzes the effects of the machining conditions (ultrasonic power, feed rate, spindle speed, and tool diameter) on the performance parameters (cutting force, tool wear, overcut error, and cylindricity error), while drilling high precision holes on the workpiece made of Ti6Al4V alloys using rotary ultrasonic machining (RUM). Numerical results were obtained by conducting experiments following the design of an experiment procedure. The effects of the machining conditions on each performance parameter have been determined by constructing a set of possibility distributions (i.e., trapezoidal fuzzy numbers) from the experimental data. A possibility distribution is a probability-distribution-neural representation of uncertainty, and is effective in quantifying the uncertainty underlying physical quantities when there is a limited number of data points which is the case here. Lastly, the optimal machining conditions have been identified using these possibility distributions.

Intermittent and Continuous Rotary Ultrasonic Machining of K9 Glass: An Experimental Investigation

“…Chowdhury et al conducted an experiment by drilling high precision holes in Ti6Al4V using RUM and constructed a set of possibility distributions in order to represent the uncertainty in the output variables to determine the effects of the input variables on output variables quantitatively [19].…”

Porosity, Surface Quality, Microhardness and Microstructure of Selective Laser Melted 316L Stainless Steel Resulting from Finish Machining

“…Fabricated components are expected to have a smooth surface with lower surface roughness in the conventional manufacturing process [35,36], and AM should be able to offer the same quality in order to become an alternative approach in the Although selective laser melting is an emerging approach due to its many advantages when compared to traditional manufacturing processes, one of the limitations is to produces a surface quality that is not within an acceptable range [34]. Fabricated components are expected to have a smooth surface with lower surface roughness in the conventional manufacturing process [35,36], and AM should be able to offer the same quality in order to become an alternative approach in the manufacturing industry. Average surface roughness (Ra) of SLMed as-built 316L stainless steel is approximately 7 ± 1 µm, as shown in Figure 6.…”

Machining Forces Due to Turning of Bimetallic Objects Made of Aluminum, Titanium, Cast Iron, and Mild/Stainless Steel

“…In this article, the formulations up to (A7) were used, i.e., the regular fuzzy number was not constructed. The triangular fuzzy numbers are particularly important when the optimization of cutting conditions is carried out using the experimental data obtained by using a statistical procedure (e.g., design of experiment), as shown in [26].…”

“…In particular, the possibility distributions show that the use of a low feed and low cutting speed and the cutting direction hard-to-soft is a better option for reducing the cutting force and its uncertainty. To be more specific, the uncertainty in the cutting forces was studied by constructing the possibility distributions [25,26] (probability-distribution-neutral representation of uncertainty) for the cutting forces, as shown in Figure 4. Appendix B shows the mathematical settings for inducing a possibility distribution from a set of numerical data.…”