Study on Influence of Ultrasonic Vibration on the Ultra-Precision Turning of Ti6Al4V Alloy Based on Simulation and Experiment

Hu, Keman; Lo, Sio-Long; Wu, Hongbing; To, Suet

doi:10.1109/access.2019.2896731

Cited by 30 publications

(18 citation statements)

References 30 publications

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“…Thepsonthi [ 17 ] simulated the micro-end milling of titanium alloy using an established 3D finite element model. Hu [ 18 ] used the finite element technique to study the mechanism of chip formation in the ultrasonic assist ultra-precision cutting of titanium alloy. Wu [ 19 ] developed a 3D milling model to simulate the cutting model to investigate the cutting phenomenon of titanium alloy.…”

Section: Introductionmentioning

confidence: 99%

Cutting mechanism of straight-tooth milling process of titanium alloy TC21 based on simulation and experiment

Zhang

Pei

2021

PLoS ONE

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Due to the characteristics of high strength, high chemical activity and low heat conduction, titanium alloy materials are generally difficult to machine. As a typical titanium alloy with higher strength and lower heat conductivity, the machinability of titanium alloy TC21 is very poor and its cutting process is companied with larger cutting force and rapid tool wear. Straight-tooth milling tool is often used to cut the groove and side surface in the titanium alloy parts. And the milling method can be used to investigate the cutting mechanism because the cutting force has only two components and the better chip morphology is obtained. To investigate the straight-tooth milling process of TC21 alloy, a series of milling force experiments have been done. In addition, a 3D finite element model (FEM) for the straight-tooth milling process of TC21 alloy is presented to simulate the milling process. In the model, the constitutive material model, the failure model, the friction model and the heat transfer model were adopted. Through the simulation, chip formation, stress distribution, cutting force and milling temperature were obtained. The cutting force reaches its maximum when the spindle speed reaches about 13000 rpm, and then decreases as the speed continues to increase. The results confirmed that the similar “Salomon” phenomenon existed in the cutting process of TC21 alloy.

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Section: Introductionmentioning

confidence: 99%

Cutting mechanism of straight-tooth milling process of titanium alloy TC21 based on simulation and experiment

Zhang

Pei

2021

PLoS ONE

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“…Yan et al 30,31 studied the effects of the continuous minimum quantity lubrication with ultrasonic vibration in turning of titanium alloy, and the results illustrated that UAT lowered cutting force due to the combined advantages of lubrication and vibration, furthermore the cutting force was decreased with the cutting speed and tool frequency increased. Hu et al 32 researched the influence of ultrasonic vibration on the ultra-precision turning of Ti6Al4V based on simulation and experiment, and it demonstrated that UAT could reduce the cutting force and residual stress compared to CT.…”

Section: Introductionmentioning

confidence: 99%

Experimental study on cutting force in ultrasonic vibration-assisted turning of 304 austenitic stainless steel

Wan

Zou

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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The generation mechanism of cutting force in ultrasonic vibration assisted turning (UAT), with the composition and decomposition of cutting force is discussed in this paper, and the model of cutting force in UAT is established based on the mechanism of UAT. The force measuring test system is designed on the basis of the established machining system of UAT. The contrast experiments for turning the workpiece of 304 austenitic stainless steel are conducted with and without ultrasonic vibration under different technological parameters. Furthermore, the relational model and correlation between technological parameters and cutting force is obtained by regression analysis and variance analysis. Thereby, the mutual relation among these technological parameters is effectively controlled, which contributes to achieving the high quality and high efficient processing. Simultaneously, the influences of single technological parameter with the interaction between technological parameters on cutting force are researched and analyzed. The results prove that the cutting force is reduced significantly with the aid of ultrasonic vibration in turning and the choice of the proper ultrasonic amplitude, there is an optimal range of ultrasonic amplitudes as well. Meanwhile, the cutting parameters have great influence on cutting force, among which depth of cut has the superior influence, then the cutting speed, and feed rate has the minimal influence. Moreover, cutting parameters should not be too large, UAT is mainly used for semi-finishing or finishing at medium-low speed. UAT will get more ideal machining effect if cutting parameters are chosen properly.

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“…At the same time, many methods were presented to reduce the tool wear and improve the cutting quality of titanium alloys in the cutting process. 15–22 Braham et al. 15 used the laser-assisted machining to improve the machinability of titanium alloys by using the thermal softening effect and the investigation showed that the chip formation mechanisms are also changed by increasing the sawteeth frequency when using laser assistance.…”

Section: Introductionmentioning

confidence: 99%

Investigation of the turning process of the TC21 titanium alloy: Experimental analysis and 3D simulation

Pei

Shu

2020

Proceedings of the Institution of Mechanical Engineers, Part E:

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Titanium alloys are widely used in the aerospace industry due to their superior properties such as high strength and low density. As a new titanium alloy with higher strength and lower heat conductivity, titanium alloy TC21 is very difficult to cut and the cutting mechanism of this alloy needs to be investigated deeply. In the paper, to observe the cutting phenomenon in the turning process of TC21 alloy, a series of turning experiments have been performed to investigate the turning process of TC21 alloy. Further, the influence of some important turning parameters (cutting speed, feed speed, depth of cut and rake angle) on cutting force and chip morphology is well analyzed through the experiments. In addition, a 3D finite element model for turning was established using the software ABAQUS for helping to analyze the turning process of TC21. Through simulation, cutting force, chip formation and temperature distribution of TC21 alloy in the turning process have been achieved. At the same time, simulated cutting forces and chip morphology were compared with the results of experiment. The results of experiments showed that the chip of TC21 alloy in turning process is serrated and the rake angle of tool has the obvious effect on the chip morphology.

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Study on Influence of Ultrasonic Vibration on the Ultra-Precision Turning of Ti6Al4V Alloy Based on Simulation and Experiment

Cited by 30 publications

References 30 publications

Cutting mechanism of straight-tooth milling process of titanium alloy TC21 based on simulation and experiment

Cutting mechanism of straight-tooth milling process of titanium alloy TC21 based on simulation and experiment

Experimental study on cutting force in ultrasonic vibration-assisted turning of 304 austenitic stainless steel

Investigation of the turning process of the TC21 titanium alloy: Experimental analysis and 3D simulation

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