Experimental Study on Ultrasonic-Assisted End Milling Forces in 2195 Aluminum-Lithium Alloy

Abstract

To achieve high-quality machining of the 2195 aluminum-lithium alloy, this paper presents an experimental study on the effect of milling processing parameters on milling forces and surface topography, during which conventional milling and longitudinal-torsional ultrasonic vibration milling of the 2195 Al-Li alloy were performed. The characterization of the tool tip trajectory illustrates some of the advantages of ultrasonic machining, which include variable depth of cut and tool chip pulling. The differences in milling forces between conventional milling and longitudinal-torsional ultrasonic vibration machining were compared using orthogonal tests, and the effect of ultrasonic vibration on milling forces was investigated in detail. The maximum reduction of milling force Fy in the feed direction under the influence of torsional vibration is 62% and 54% for larger feed per tooth and cutting depth, respectively. The high-frequency impact generated by the longitudinal vibration not only reduces the chip accumulation on the surface, but also smooths out the tool-tooth scratches and creates a regular surface profile. In addition, the characteristics of the milling force signals of the two machining methods were analyzed, and the analysis of the spectrum of the collected milling forces revealed that the ultrasonic vibration caused the high-frequency components of the milling forces Fy and Fz. The orthogonal result analysis and single-factor result analysis verified the superiority of ultrasonic machining, provided parameter selection for subsequent aluminum-lithium alloy machining, and bridged the gap of longitudinal torsional ultrasonic vibration machining of 2195 aluminum-lithium alloy in the study of milling force.

An Analytical and Experimental Study on Cutting Characteristics and Transient Cutting Force Modeling in Feed Directional Ultrasonic Vibration-Assisted Cutting of High Strength Alloys

“…Based on the ultrasonic vibration amplitude and experimental cutting parameters in published Refs. [ 6 , 7 , 8 , 9 , 10 , 11 ], the cutting parameters for the experiment are planned and presented in Table 3 . Each cutting experiment has repeated ten times and the experimental cutting force are determined by averaging those cutting force value.…”

“…The reduction of cutting force was reported to be caused by intermittent cutting [ 7 ]. At the same time, the intermittent cutting has also been deemed to contribute to cutting force reduction in radial high-speed ultrasonic vibration cutting [ 8 ]. Moreover, it was reported that low-frequency vibration-assisted machining could improve the machinability of difficult-to-cut materials in which intermittent cutting may not occur [ 9 ].…”

Investigation of the Combined Effects of Ultrasonic Vibration-Assisted Machining and Minimum Quantity Lubrication on Al7075-T6

“…Another research was conducted by Shen et al [12] on the UVAM of aluminum alloy 2A12 in slot milling operation, and the results showed that UVAM reduced the vertical side wall surface roughness; however, the slot bottom surfaces were adversely afected by UVAM, and this is mainly due to the vibrational direction. Wang et al [13] conducted a study on the cutting force comparison between CM and UVAM in 2195 aluminum alloy, and the study showed that UVAM reduced the cutting force component F y up to 62% when the optimum machining conditions were selected; also, due to the reduction of the cutting forces, the surface topography found enhanced compared to CM.…”

Research on a novel non-uniform and asymmetric ultrasonic vibration system and Machined surface characteristics

“…By applying ultrasonic vibration to the tool to remove materials intermittently, the purpose of improving machining efficiency, reducing cutting force and reducing tool wear was realized, which is the characteristic of ultrasonic vibration cutting [1]. Nowadays, ultrasonic vibration cutting has been successfully applied in many processing fields, such as turning [2], milling [3] and drilling [4]. Due to the characteristics of high processing temperature and large cutting force, it is easy to have low processing efficiency and poor surface quality when machining hard and brittle materials such as titanium alloy, ceramics and fiber reinforced composites by traditional cutting methods [5].…”