Multiobjective optimization of processing parameters in longitudinal-torsion ultrasonic assisted milling of Ti-6Al-4V

Niu, Ying; Jiao, Feng; Zhao, Bo; Wang, Dong

doi:10.1007/s00170-017-0871-3

Cited by 39 publications

(17 citation statements)

References 22 publications

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“…The chemical composition of the workpiece material, Ti-6Al-4V was presented in Ref. [15]. The size of the rectangular workpiece used was 30 mm × 15 mm × 6 mm.…”

Section: Resultsmentioning

confidence: 99%

“…On the contrary, in longitudinal-torsional ultrasonic vibration-assisted milling (LTUM), due to the cutting edge moving in three-dimensional space, extrusion friction between the tool flank and the machined surface is effectively avoided. In addition, the shear angle is increased and the average cutting force and cutting temperature in processing are (further) reduced [15,16], which is important in anti-fatigue manufacturing of high performance components.…”

Section: Introductionmentioning

confidence: 99%

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Investigation of Cutting Force in Longitudinal-Torsional Ultrasonic-Assisted Milling of Ti-6Al-4V

et al. 2019

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In this study, we propose a longitudinal-torsion ultrasonic-assisted milling (LTUM) machining method for difficult-to-cut materials—such as titanium alloy—in order to realize anti-fatigue manufacturing. In addition, a theoretical prediction model of cutting force is established. To achieve this, we used the cutting edge trajectory of LTUM to reveal the difference in trajectory between LTUM and traditional milling (TM). Then, an undeformed chip thickness (UCT) model of LTUM was constructed. From this, the cutting force model was able to be established. A series of experiments were subsequently carried out to verify this LTUM cutting force model. Based on the established model, the influence of several parameters on cutting force was analyzed. The results showed that the established theoretical model of cutting force was in agreement with the experimental results, and that, compared to TM, the cutting force was lower in LTUM. Specifically, the cutting force in the feed direction, Fx, decreased by 24.8%, while the cutting force in the width of cut direction Fy, decreased by 29.9%.

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“…The chemical composition of the workpiece material, Ti-6Al-4V was presented in Ref. [15]. The size of the rectangular workpiece used was 30 mm × 15 mm × 6 mm.…”

Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Investigation of Cutting Force in Longitudinal-Torsional Ultrasonic-Assisted Milling of Ti-6Al-4V

et al. 2019

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“…Substituting equation 5into equations (1) and 4, the frequency equation of transducer with a quarter wavelength on the left side can be deduced, which can be expressed as…”

Section: Derivation Of Left-hand Frequency Equationmentioning

confidence: 99%

“…The longitudinal-torsional (L-T) composite ultrasonic vibration-assisted machining has more advantages than other vibration modes and can improve the cutting process and quality significantly. [1][2][3] Tang and Zhao [4][5][6] have designed a new type of L-T composite ultrasonic vibration system and analyzed the stability of the system. The research methods of ultrasonic vibration system include the analytical method, 7 finite element method, 8 equivalent circuit method, 9 fourterminal network method, 10,11 and transmission line equation method.…”

Section: Introductionmentioning

confidence: 99%

Design, simulation, and adjustment of the longitudinal–torsional composite integrated ultrasonic variable amplitude system

Zhang

Zhao

Niu

2018

Advances in Mechanical Engineering

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For the longitudinal-torsional composite integrated ultrasonic variable amplitude system with the longitudinal-torsional resonance produced by helical slots in the cone of the launch section, the theoretical design, finite element simulation, and experimental study are carried out. The performed analysis of the helical slot structural characteristics revealed that slot depth, helical angle, and slot width have a strong effect on the natural frequency and ratio of the torsionallongitudinal amplitude. A credible technique for adjusting the deviation of the actual system natural frequency from the theoretical design value by traditional method is proposed based on the adjustment theory of non-uniform medium adopted. The experimentally proved reduction of the above deviation strongly suggests that the approach proposed in this article provides effective theoretical guidance and experimental basis for the study of longitudinal-torsional composite integral ultrasonic variable amplitude system.

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“…As an intermittent cutting method, ultrasonic vibration machining (UAM) has been widely discussed for its ability to open the tool-workpiece contact area intermittently. As one of the typical UAM processes, the ultrasonic-assisted milling technique has been widely applied to machine difficult-to-cut alloys for its superiority in expanding tool life, lowering cutting force and delivering better surface quality [18][19][20][21][22][23][24]. In order to obtain the intermittent cutting mode between the tool and the workpiece in UAM, its relative velocity in cutting direction should be controlled as the opposite to the tool rotation direction periodically.…”

Section: Introductionmentioning

confidence: 99%

High-Speed Rotary Ultrasonic Elliptical Milling of Ti-6Al-4V Using High-Pressure Coolant

Zhang

Guo³

et al. 2020

Metals

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High-speed rotary ultrasonic elliptical milling (HRUEM), as a novel ultrasonic vibration cutting method, has been introduced in milling the alloy Ti-6Al-4V. The application of ultrasonic vibration in high-speed milling can help open the cutting contact area intermittently. New cutting effects will happen with full use of the separation effect brought by ultrasonic vibration and the cooling effect brought by a high-pressure coolant (HPC). On the basis of that, this paper firstly introduces HPC into HRUEM of Ti-6Al-4V in the open literature and analyzes the tool-workpiece separation cooling mechanism in HRUEM, including kinematic analysis of tool tip trajectories, tool-workpiece separation principles and high-pressure coolant effects. We have conducted a comprehensive experimental study and the results show when HPC is increased to 200 bar, compared to conventional milling (CM), the tool life in HUREM can be extended by 6.6 times at 80 m/min, 4.2 times at 120 m/min and 2.4 times at 160 m/min. The maximum material removal volume (MRV) for a given new end mill in HRUEM is increased by 657% approximately. When the cutting speed is 80 m/min, the cutting temperature of the workpiece in HRUEM is reduced by 24.1% compared to that of CM. By applying the combination of HPC and tool-workpiece periodic separation, we can significantly enhance the cooling and lubrication efficiency in HRUEM and also inhibit the tool wear mode of adhesive wear typically occurred in CM.

show abstract

Multiobjective optimization of processing parameters in longitudinal-torsion ultrasonic assisted milling of Ti-6Al-4V

Cited by 39 publications

References 22 publications

Investigation of Cutting Force in Longitudinal-Torsional Ultrasonic-Assisted Milling of Ti-6Al-4V

Investigation of Cutting Force in Longitudinal-Torsional Ultrasonic-Assisted Milling of Ti-6Al-4V

Design, simulation, and adjustment of the longitudinal–torsional composite integrated ultrasonic variable amplitude system

High-Speed Rotary Ultrasonic Elliptical Milling of Ti-6Al-4V Using High-Pressure Coolant

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