Finite element simulation and experimental investigation of tool temperature during ultrasonically assisted turning of aerospace aluminum using multicoated carbide inserts

The machining of Titanium alloy, Ti-6Al-4V has got an extensive attention from industries like aerospace, medical, and biomedical plants due its unique properties like high strength at elevated temperature and better strength to weight ratio. Still, properties like reduced thermal conductivity, affinity to react with the tool and work hardening make difficult to cut it by conventional turning process. Ultrasonic vibration-assisted turning (UVAT) is one of the advanced turning method in which tool is allowed to vibrate with ultrasonic frequency (~ 20 kHz) with small amplitude and hence converting the continuous cutting to an intermittent cutting process. In the present work a horn (acts as an amplifier as well as a tool holder) with inserted tool tip is designed and FEM analysis has been done for its suitability for the process. The dynamic analysis has also been performed to find out the stress distribution in both parts under cyclic loading conditions. It enables to locate the highly stressed nodal regions. Experimental investigation has been carried out for both conventional turning (CT) and UVAT processes to demonstrate effects of various inputs on the output responses like cutting forces, surface roughness, tool wear and temperature rise in UVAT. Additionally, a 3D finite element model for UVAT and CT has been prepared. The simulation results like force and steady state tool tip temperature have also been validated with the experimental results and found to be in good agreement. The advantages of UVAT process have been discovered in terms of reduction in the cutting forces and surface roughness for the used Ti-6Al-4V workpiece.

Section: Surface Finishsupporting

confidence: 80%

Ultrasonic vibration-assisted turning of Titanium alloy Ti–6Al–4V: numerical and experimental investigations

Kandi

Sahoo

2020

“…Especially in optical applications, it has been used to produce complex shapes [17,18]. Studies on 2D vibration are focused on micro-machining of materials such as glass and ceramics, while studies on 1D vibration applications are used for aerospace materials that a machine using conventional methods [10,11,13,19,20].…”

Section: Ultrasonic Assisted Machiningmentioning

confidence: 99%

Numerical investigation of hot ultrasonic assisted turning of aviation alloys

Sofuoğlu

Çakir

Gürgen

et al. 2018

Aviation alloys exhibit superior properties such as high-strength-to-weight ratio and corrosion resistance but these alloys possess poor machinability. To overcome this disadvantage, new machining methods (Ultrasonic assisted machining, hot machining, etc.) are developed. Hot ultrasonic assisted turning (HUAT) is a new hybrid machining method which changes the cutting system between tool and workpiece, therefore, reduced cutting forces and better surface finish for workpiece are obtained. In this study, 2D finite element (FE) analysis is carried out to investigate the effects of these machining methods on titanium and Hastelloy-X alloys in terms of cutting forces, cutting tool temperatures and effective stresses. DEFORM-2D software is used during analyses. In addition, an experimental study is conducted to verify numerical results. During verification, cutting tool temperature is taken into consideration. It is confirmed that HUAT technique reduces cutting forces and effective stress significantly but cutting temperature increases compared to conventional and ultrasonic assisted turning. Keywords Finite element modeling Á Hot ultrasonic assisted machining Á Titanium alloys Á Ultrasonic assisted machining Á Hot machining Á Hastelloy-X

“…Micro-USM has proved its efficacy to machine complex shapes in all types of hard and brittle materials. Moreover, the assistance of ultrasonic energy enhances the performance of both conventional and non-conventional machining methods (i.e., turning, milling and drilling) during machining of difficult-to-cut high strength materials/alloys [8][9][10][11][12][13][14][15][16][17].…”

Section: Introductionmentioning

confidence: 99%

Effect of tool materials on performance of rotary tool micro-USM process during fabrication of microchannels

Kumar

Dvivedi

2019

The tool wear affects the efficiency of micro-USM process and the quality of machined micro-features. In this research endeavor, wear mechanism of soft/ductile and hard/brittle tool materials is investigated comprehensively. Stainless steel-304 (SS-304) and tungsten carbide (WC) were selected as tool materials for rotary tool micro-USM (RT-MUSM) process. The effect of tool material properties on tool wear and performance of RT-MUSM process is also discussed. The effect of RT-MUSM process parameters, viz. rotation speed, feed rate, power rating and slurry concentration on material removal rate (MRR), depth of channel (DOC) and width over cut (WOC) are reported. The experimental results showed that SS-304 tool worn out rapidly due to plastic deformation followed by strain hardening. The superior properties of WC such as high wear resistance, compressive strength and good acoustic property led to reduction in tool wear and thereby significantly improved the performance of RT-MUSM. Additionally, multi-response optimization was applied to obtain maximum MRR, DOC and minimum WOC simultaneously.