Surface and subsurface analysis of TC18 titanium alloy subject to longitudinal-torsional ultrasonic vibration-assisted end milling

Xie, Weibo; Wang, Xikui; Zhao, Bo; Li, Guangxi; Xie, Zongwu

doi:10.1016/j.jallcom.2022.167259

Cited by 15 publications

(3 citation statements)

References 31 publications

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“…In recent years, an increasing number of researchers have focused on the effects of ultrasonic vibration on the interior of workpieces because the vibration results in residual stress inside the machined surface, which affects the machining performance of the workpiece [75,76]. Xie et al [77] examined the machining pattern of longitudinal torsional UVAM of TC18 titanium alloys by applying vertical ultrasonic vibration on an end mill. The continuous machining surface impact changed the grain morphology and microstructure inside the workpiece.…”

Section: Tool Ultrasonic Vibration-assisted Millingmentioning

confidence: 99%

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Zhao,

Ding

et al. 2024

Int. J. Extrem. Manuf.

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Difficult-to-cut materials such as titanium alloys, high-temperature alloys, metal/ceramic/polymer-matrix composites, hard and brittle materials, as well as geometrically complex components such as thin-walled structures, micro channels and complex surfaces, are widely used in aerospace community. Mechanical machining is the main material removal process and responsible for the vast majority of material removal for aerospace components. Nevertheless, it encounters many problems in terms of severe and rapid tool wear, low machining efficiency, and deteriorated surface integrity. Nontraditional energy-assisted mechanical machining is a hybrid process in which nontraditional energies, e.g., vibration, laser, electric, etc., are applied to improve the machinability of local material and decrease burden of mechanical machining. It provides a feasible and promising way for improving machinability and surface quality, reducing process forces, and prolonging tool life, etc. However, systematic reviews of this technology are lacking with respect to the current research status and development direction. This paper reviews recent progress in nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community. It focuses on the processing principles, material responses under nontraditional energy, resultant forces and temperatures, material removal mechanisms and applications of these processes including vibration-, laser-, electric-, magnetic-, chemical-, cryogenic cooling-, and hybrid nontraditional energies-assisted mechanical machining. Eventually, a comprehensive summary of the principles, advantages and limitations for each hybrid process is provided, and future perspectives on forward design, device development and sustainability of nontraditional energy-assisted mechanical machining processes are discussed.

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Section: Tool Ultrasonic Vibration-assisted Millingmentioning

confidence: 99%

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Zhao,

Ding

et al. 2024

Int. J. Extrem. Manuf.

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“…In addition, nonlinear fitting based on Yoshida et. al [6] was used to obtained the relationship between elastic modulus (E) and true strain (εtru), as shown in Fig. 5c and Eq.…”

Section: Mechanical Test and Materials Parameter Of Tc4 Titanium Alloymentioning

confidence: 99%

“…Milling process is used to manufacture such components due to its high degree of machining freedom, although surface quality and dimensional accuracy after milling ensure service safety and performance of components [4][5][6], the deep and narrow V-shaped channel structure of such components also increases the milling difficult and decreases the milling efficiency [7,8]. Therefore, a collaborative manufacturing method of pre-plastic forming and milling was used to solve these problems, i.e., under the premise of ensuring the dimensional accuracy and surface quality of finish milling, combining plastic forming to improve the rough milling efficiency and milling difficulty, but the structural characteristics of thin-walled and variable thickness also will bring the problems of residual stress and springback after pre-plastic forming.…”

mentioning

confidence: 99%

Gradient thickness-dependent distribution of residual stress and springback of thin-walled TC4 titanium alloy sheet with variable thickness in collaborative manufacturing process of pre-plastic forming and milling

SHU,

REN,

ZHANG

et al. 2024

Preprint

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Thin-walled sheet components with variable thickness and complex curved surface are expanding considerably in the advanced manufacturing field of aerospace industry due to its aerodynamic shape and light-weight characteristics, and collaborative manufacturing method of pre-plastic forming and milling was used to solve the problems of low rough milling efficiency and large milling difficult of such components. However, the structural characteristics of thin-walled and variable thickness brought the problems of residual stress and springback after pre-plastic forming, which impacted the milling quality and increased milling allowance in subsequent milling. In this work, based on three-point bending tests of thin-walled TC4 titanium alloy sheets with different ratio of thickness variation (ζ) and its Finite Element Analyze (FEA), gradient thickness-dependent distribution of residual stress and springback after pre-plastic forming was systematically studied. The results showed that with the ζ increasing from 1 to 6, difference of residual stress (Δσres) between both sides increased from 0 to 356.81 MPa, difference of springback (ΔS) between both sides increased 0 to 0.23 mm, and Springback Angle (SA) increased from 11.02 ° to 11.88 °, which was due to the increasing of stress component along the breadth direction and the decreasing of strain component along the thickness direction, and specimen #5 (ζ = 3) had more uniform distribution of residual stress. In addition, through considering the decay of elastic modulus (E) after plastic deformation, absolute error of SA of specimen #6 (ζ = 6) was reduced from 1.98 ° to 0.95 °.

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Introduction

Ding,

Zhao,

Zhao

et al. 2024

Hybrid-Energy Cutting of Aerospace Alloys

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Surface and subsurface analysis of TC18 titanium alloy subject to longitudinal-torsional ultrasonic vibration-assisted end milling

Cited by 15 publications

References 31 publications

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Gradient thickness-dependent distribution of residual stress and springback of thin-walled TC4 titanium alloy sheet with variable thickness in collaborative manufacturing process of pre-plastic forming and milling

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