Ultrasonic vibration-assisted turning of Titanium alloy Ti–6Al–4V: numerical and experimental investigations

Abstract

The machining of Titanium alloy, Ti-6Al-4V has got an extensive attention from industries like aerospace, medical, and biomedical plants due its unique properties like high strength at elevated temperature and better strength to weight ratio. Still, properties like reduced thermal conductivity, affinity to react with the tool and work hardening make difficult to cut it by conventional turning process. Ultrasonic vibration-assisted turning (UVAT) is one of the advanced turning method in which tool is allowed to vibrate with ultrasonic frequency (~ 20 kHz) with small amplitude and hence converting the continuous cutting to an intermittent cutting process. In the present work a horn (acts as an amplifier as well as a tool holder) with inserted tool tip is designed and FEM analysis has been done for its suitability for the process. The dynamic analysis has also been performed to find out the stress distribution in both parts under cyclic loading conditions. It enables to locate the highly stressed nodal regions. Experimental investigation has been carried out for both conventional turning (CT) and UVAT processes to demonstrate effects of various inputs on the output responses like cutting forces, surface roughness, tool wear and temperature rise in UVAT. Additionally, a 3D finite element model for UVAT and CT has been prepared. The simulation results like force and steady state tool tip temperature have also been validated with the experimental results and found to be in good agreement. The advantages of UVAT process have been discovered in terms of reduction in the cutting forces and surface roughness for the used Ti-6Al-4V workpiece.

Radial direction ultrasonic-vibration and laser assisted turning of Al3003 alloy

“…The EN8 carbon steel was used as the booster material and it was fabricated in a cylindrical shape. The length of the cylindrical booster was calculated as [30] ( )…”

Effect of ultrasonic vibration on ultra precision diamond turning of polycrystalline zinc sulfide

“…In addition, regular ultrasonic vibration creates uniform and flat chips, which lowers the degree of deformation of the material [5]. Previous studies have shown that ultrasonic vibration cutting methods perform better at low cutting speeds [6,7]. This study applies ultrasonic vibration cutting to mechanically process polycrystalline zinc sulfide material, observing changes in surface characteristics with varying cutting speeds and analyzing the springback issue observed in conventional machining.…”

Experimental investigation on the machining performance of AISI D2 tool steel during ultrasonic-assisted turning under dry and MQL conditions

“…In contrast to continuous turning, the tool life improved multifold due to the discontinuous cutting nature. 2 Kandi et al 3 examined the effect of the input variables on the surface finish and tool wear in the UAT and CT of Ti6Al4V alloy. The authors reported that the surface finish obtained in ultrasonic vibration-assisted turning (UVAT) was much lower than CT.…”