Effect of ultrasonic vibration on finished quality in ultrasonic vibration assisted micromilling of Inconel718

In the traditional micromilling(TMM) of Inconel718 alloy, due to the influence of material plas ticity and size effect, relatively large burr will be produced. In order to solve the burr proble m in micromilling, ultrasonic vibration in feed direction is applied to the workpiece to complet e vibration cutting. Combined with trajectory simulation and cutting experiment, the burr forma tion mechanism of TMM and ultrasonic vibration assisted micromilling(UVAMM) was studied.The results show that when the ratio of amplitude(A) to feed per tooth(ƒz) is greater than 0.5, continuous cutting changes to intermittent cutting. Compared with TMM, UVAMM improves ch ip breaking ability, facilitates the propagation of burr crack and effectively inhibits the formatio n of burr. However, due to the influence of cutting edge radius, A/ƒz should be set larger. Wh en the chip breaking condition is reached, the burr shape is usually tearing or flocculent. Unde r the conditions of low speed(n), large ƒz and large A, the burr suppression is more obvious.

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“…The minimum cutting thickness of Inconel718 is expressed by Eq. ( 1) [31] and the instantaneous cutting thickness is expressed by Eq. ( 2).…”

Section: Chip Formation Processmentioning

confidence: 99%

Effect of cutting parameters on chips and burrs formation with traditional micromilling and ultrasonic vibration assisted micromilling

Yuan

Fang

Zhang

et al. 2022

Int J Adv Manuf Technol

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“…The plane local coordinate system O i X i Z i is established with the lowest point of the abrasive as its origin. The cutting path of a single abrasive particle in the grinding process can be defined as equation (11), as follows:…”

Section: Mathematical Model Of Abrasive Trajectorymentioning

confidence: 99%

“…8,9 Meanwhile, the machinability of the workpiece material is improved due to the ultrasonic vibration. [10][11][12] In TUAG, the surface topography and roughness are problems that cause concern. However, reports on the characterization of the surface topography ground by TUAG are fewer compared with reports on the other two types of one-dimensional ultrasonic vibration, thereby restricting TUAG's application.…”

Section: Introductionmentioning

confidence: 99%

Generation mechanism modeling of surface topography in tangential ultrasonic vibration-assisted grinding with green silicon carbide abrasive wheel

Qiu

Yin

Cao

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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Tangential ultrasonic vibration-assisted grinding (TUAG) has a wide prospect in machining difficult-to-machine materials. However, the surface generation mechanism in TUAG is not fully recovered. This study proposes an analytical model of the surface topography produced by TUAG. Based on the model, the surface topography and roughness are predicted and experimentally verified. In addition, the influence of the grinding parameters on the surface topography is analyzed. The predicted surface topography well coincides with experimental measurements, and the prediction error in surface roughness Ra by the proposed model is less than 5%. Compared with conventional grinding, TUAG produces a surface with more uniform scratches and surface roughness Ra was reduced by up to 27% with the proper parameters. However, the improvement of surface roughness in TUAG is weakened when grinding speed or depth of cut increases. Moreover, the influence of the ultrasonic vibration amplitude on the surface roughness is not monotonous. With the grinding parameters selected in this study, TUAG with an ultrasonic amplitude of 7.5 μm produces the minimum surface roughness.

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“…Titanium alloys forming and processing is extremely di cult because its high strength and high speci c stiffness leading to tool wear and irregular material removal phenomenon. Irregular material removal will lead to increased surface roughness and processing defects, which will eventually lead to surface cracks and workpiece failure [9][10][11]. Therefore, reducing the processing defects and improving the uniformity of material removal is vital to improve machining performance and extend the service life of the workpiece for di cult-to-process materials.…”

Section: Introductionmentioning

confidence: 99%

Surface feature and material removal in ultrasonic vibration-assisted slot-milling of Ti–6Al–4 V titanium alloy

Chang

Duan

2022

Int J Adv Manuf Technol

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The continuous optimization of processing technology and evaluation methods is an important way to achieve high processing quality and processing e ciency for di cult-to-process materials. To solve the problem of frequent defects on the slot, the ultrasonic vibration assisted slot-milling (UVASM) technology was developed for processing titanium alloy. Simultaneously, comparative experiments were carried out between UVASM and conventional slot-milling (CSM), in terms of surface features of slot bottom and slot sidewall, cutting force, tool trajectory, chip morphology, and micro-hardness. The results show that uniform vibration micro-texture could signi cantly improve surface topography of slot bottom in UVASM, while numerous tool feed trajectories and observable machining defects detract from the surface quality in CSM. The UVASM can greatly reduce material spalling and edge breakage, thereby maintaining a smooth and regular edge pro le of slot sidewall. The tool tips trajectories of two machining methods are highly corresponding to the machining textures of the slot sidewall surface. There is a high-frequency and small-amplitude force uctuation signal on the axial force waveform in UVASM, which can reduce the instantaneous maximum milling force and milling force in the stable stage by 8.7% and 12.2%, respectively. The UVASM has a better chip breaking effect and surface anti-scratch effect and the UVASM can obtain higher surface micro-hardness and deeper plastic deformation layer than those of CSM. In summary, the multi-dimensional evaluation of slot processing status has been completed and the processing quality of the slot has been improved.

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Effect of ultrasonic vibration on finished quality in ultrasonic vibration assisted micromilling of Inconel718

Cited by 42 publications

References 29 publications

Effect of cutting parameters on chips and burrs formation with traditional micromilling and ultrasonic vibration assisted micromilling

Effect of cutting parameters on chips and burrs formation with traditional micromilling and ultrasonic vibration assisted micromilling

Generation mechanism modeling of surface topography in tangential ultrasonic vibration-assisted grinding with green silicon carbide abrasive wheel

Surface feature and material removal in ultrasonic vibration-assisted slot-milling of Ti–6Al–4 V titanium alloy

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