Research on cutting force and surface integrity of TC18 titanium alloy by longitudinal ultrasonic vibration assisted milling

Xie, Weibo; Wang, Xikui; Liu, Erbo; Wang, Jian; Tang, Xiaobin; Li, Guangxi; Zhang, Jian; Yang, Liquan; Chai, Yongbo; Zhao, Bo

doi:10.1007/s00170-021-08532-y

Cited by 18 publications

(12 citation statements)

References 37 publications

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“…The reason is that although the instantaneous cutting thickness of UVAMM is sometimes greater than TMM, because UVAMM is intermittent cutting, it is not conducive to the accumulation of cutting heat, reduces the heat generated by friction between the tool tip and the material, and provides more sufficient time for the heat dissipation process. Wang et al [ 30 ] also pointed out that additional ultrasonic vibration can effectively increase the diffusion time and diffusion space of cutting temperature.…”

Section: Resultsmentioning

confidence: 99%

Study on the Mechanism of Burr Formation by Simulation and Experiment in Ultrasonic Vibration-Assisted Micromilling

et al. 2023

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Due to the strong plasticity of Inconel 718 and the significant size effect of micromachining, a large number of burrs will be produced in traditional processing. The addition of ultrasonic vibration during machining can reduce the burr problem. The mechanism of burr generation in traditional micromilling (TMM) and ultrasonic vibration-assisted micromilling (UVAMM) was analyzed by simulation, and verified by corresponding experiments. It is found that applying high-frequency ultrasonic vibration in the milling feed direction can reduce cutting temperature and cutting force, improve chip breaking ability, and reduce burr formation. When the cutting thickness will reach the minimum cutting thickness hmin, the chip will start to form. When A/ƒz > 1/2, the tracks of the two tool heads start to cut, and the chips are not continuous. Some of the best burr suppression effects were achieved under conditions of low cutting speed (Vc), feed per tooth (ƒz), and large amplitude (A). When A is 6 μm, the size and quantity of burr is the smallest. When ƒz reaches 6 μm, large continuous burrs appear at the top of the groove. The experimental results further confirm the accuracy of the simulation results and provide parameter reference.

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Section: Resultsmentioning

confidence: 99%

Study on the Mechanism of Burr Formation by Simulation and Experiment in Ultrasonic Vibration-Assisted Micromilling

et al. 2023

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“…As the vibration amplitude increased to 3.5 mm, the vibration displacement increased during the feeding process of the cutter tool, and the total contact time between the cutter tool and the specimen was prolonged, increasing F x and F y , as shown in Figure 5 d,h. Due to the longitudinal ultrasonic vibration of the cutter tool [ 27 ], F z dropped significantly. As the amplitude increased, the displacement between the cutter tool and the specimen increased, accompanied by increased generated longitudinal contact force.…”

Section: Resultsmentioning

confidence: 99%

Optimizing Processing Parameters and Surface Quality of TC18 via Ultrasonic-Assisted Milling (UAM): An Experimental Study

Xie

Wang

et al. 2023

Micromachines

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This study conducted longitudinal ultrasonic-assisted milling (UAM) tests and optimized a combination of milling technological parameters to achieve high-quality machining of TC18 titanium alloy. The motion paths of the cutter under the coupled superposition states of longitudinal ultrasonic vibration and end milling were analyzed. Based on the orthogonal test, the cutting forces, cutting temperatures, residual stresses, and surface topographical patterns of TC18 specimens under different UAM conditions (cutting speeds, feeds per tooth, cutting depths, and ultrasonic vibration amplitudes) were examined. The differences between ordinary milling and UAM in terms of machining performance were compared. Using UAM, numerous characteristics (including variable cutting thickness in the cutting area, variable cutting front angles of the tool, and the lifting of the cuttings by the tool) were optimized, reducing the average cutting force in all directions, lowering the cutting temperature, increasing the surface residual compressive stress, and significantly improving the surface morphology. Finally, fish scale bionic microtextures with clear, uniform, and regular patterns were formed on the machined surface. High-frequency vibration can improve material removal convenience, thus reducing surface roughness. The introduction of longitudinal ultrasonic vibration to the end milling process can overcome the limitations of traditional processing. The optimal combination of UAM parameters for titanium alloy machining was determined through the end milling orthogonal test with compound ultrasonic vibration, which significantly improved the surface quality of TC18 workpieces. This study provides insightful reference data for subsequent machining process optimization.

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“…Furthermore, it was observed that UVAM could effectively improve the surface morphology of (SLM) TC4 and (CL) TC4 [169], but the influence of UVAM on cutting temperature has not been studied. Gao et al [170] studied the effect of A (from 0 to 6 µm) on the cutting force, cutting temperature, and surface roughness of TC4 workpiece material at an f value of 30 kHz, as shown in Fig. 27(a) [170].…”

Section: Ultrasonic Energy Field-assisted Milling Of Titanium Alloymentioning

confidence: 99%

Energy field-assisted high-speed dry milling green machining technology for difficult-to-machine metal materials

et al. 2023

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Energy field-assisted machining technology has the potential to overcome the limitations of machining difficult-to-machine metal materials, such as poor machinability, low cutting efficiency, and high energy consumption. High-speed dry milling has emerged as a typical green processing technology due to its high processing efficiency and avoidance of cutting fluids. However, the lack of necessary cooling and lubrication in high-speed dry milling makes it difficult to meet the continuous milling requirements for difficult-to-machine metal materials. The introduction of advanced energy-field-assisted green processing technology can improve the machinability of such metallic materials and achieve efficient precision manufacturing, making it a focus of academic and industrial research. In this review, the characteristics and limitations of high-speed dry milling of difficult-to-machine metal materials, including titanium alloys, nickel-based alloys, and high-strength steel, are systematically explored. The laser energy field, ultrasonic energy field, and cryogenic minimum quantity lubrication energy fields are introduced. By analyzing the effects of changing the energy field and cutting parameters on tool wear, chip morphology, cutting force, temperature, and surface quality of the workpiece during milling, the superiority of energy-field-assisted milling of difficult-to-machine metal materials is demonstrated. Finally, the shortcomings and technical challenges of energy-field-assisted milling are summarized in detail, providing feasible ideas for realizing multi-energy field collaborative green machining of difficult-to-machine metal materials in the future.

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Research on cutting force and surface integrity of TC18 titanium alloy by longitudinal ultrasonic vibration assisted milling

Cited by 18 publications

References 37 publications

Study on the Mechanism of Burr Formation by Simulation and Experiment in Ultrasonic Vibration-Assisted Micromilling

Study on the Mechanism of Burr Formation by Simulation and Experiment in Ultrasonic Vibration-Assisted Micromilling

Optimizing Processing Parameters and Surface Quality of TC18 via Ultrasonic-Assisted Milling (UAM): An Experimental Study

Energy field-assisted high-speed dry milling green machining technology for difficult-to-machine metal materials

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