Research on Cutting Force and Surface Integrity of TC18 Titanium Alloy by Longitudinal Ultrasonic Vibration Assisted Milling

Abstract

In order to study the influence of rotational speed and amplitude on the surface integrity, TC18 titanium alloy samples were milled by the process of conventional milling and longitudinal ultrasonic vibration assisted milling. The experimental data were obtained by dynamometer, thermometer, scanning electron microscope, X-ray diffractometer and three-dimensional surface topography instrument for observation and analysis. The results show that the rotational speed has a significant effect on the cutting force, cutting temperature, surface morphology and surface residual stress. Compared with ordinary milling, the surface micro-texture produced by ultrasonic vibration milling is more regular, , and with the increase of rotational speed, the influence of ultrasonic vibration on cutting force and cutting temperature decrease. There are adverse effects on surface roughness after ultrasonic vibration superposition. The influence of ultrasonic vibration on the surface residual compressive stress is also greatly reduced when the rotational speed is greater than 2400 rpm. In addition, a certain depth of plastic deformation layer can be formed under the surface of ultrasonic vibration machining, and the depth of deformation layer increases with the increase of vibration.

Experimental Study on Cutting Force and Surface Integrity of TC4 Titanium Alloy with Longitudinal Ultrasonic-Assisted Milling

“…The experiment is to study the precision and ultra-precision machining methods of titanium alloys, in order to obtain high-performance surface quality; therefore, the selection of experimental parameters such as feed rate and cutting depth should not be too large. Based on the theory of ultrasonic-assisted precision cutting and reference to peer research, the range of processing parameters [40][41][42] was selected as follows. The cutting speed v w ranged from 20 to 50 m/min, the range of each tooth feed rate f z was 0.01 to 0.04 mm/z, the range of cutting depth a p was 0.2 to 0.5 mm, and the range of ultrasonic amplitude A was 0 to 5 µm.…”

Optimization Milling Force and Surface Roughness of Ti-6Al-4V Based on Ultrasonic-Assisted Milling (UAM): An Experimental Study

“…Ultrasonic-assisted milling (UAM) is based on the conventional milling (CM) method with the integration of ultrasonic vibration, which can convert high-frequency oscillation electrical signals into mechanical vibration using an energy transducer, thereby achieving intermittent cutting effect [ 10 , 11 ]. This technique can reduce the cutting force and improve the machining quality [ 12 , 13 , 14 , 15 ]. Recently, many studies have been conducted on the mechanism of UAM for Ti alloys.…”