Unravelling the influence of vibration on material removal and microstructure evolution in ultrasonic transversal vibration-assisted helical milling of Ti-6Al-4V holes

Geng, Daxi; Sun, Zhefei; Liu, Yihang; Liu, Lianxing; Ying, Enze; Cai, Jun; Jiang, Xinggang; Zhang, Deyuan

doi:10.1016/j.jmatprotec.2024.118320

Cited by 21 publications

(2 citation statements)

References 53 publications

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“…In the following stages, indicated by vibrational signal sets 2, 3, and 4, a decay in the vibration signal on both the right and left sides is observed, but in the final stage, indicated by vibrational set 5, the vibrational intensity of both sides is reduced and becomes equal, indicating that smoothness of the machined surface has been achieved. This behavior is according to the observations made by Geng et al [58]. They observed that tool vibration increases when there is an increase in residual material along the feed direction, which also increases the cutting force.…”

Section: Vibration Analysissupporting

confidence: 84%

“…In the first 2 minutes, two events marked by intense peaks were observed (marked by *), one at 20 s and the other at 60 s, indicating the occurrence of a small failure in the tool teeth, as the vibration intensity indicating that smoothness of the machined surface has been achieved. This behavior is according to the observations made by Geng et al [58]. They observed that tool vibration increases when there is an increase in residual material along the feed direction, which also increases the cutting force.…”

Section: Vibration Analysissupporting

confidence: 84%

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A Comparative Study of Different Milling Strategies on Productivity, Tool Wear, Surface Roughness, and Vibration

Silva,

Martinho,

Magalhães

et al. 2024

JMMP

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Strategies for obtaining deep slots in soft materials can vary significantly. Conventionally, the tool travels along the slot, removing material mainly with the side cutting edges. However, a “plunge milling” strategy is also possible, performing the cut vertically, taking advantage of the tip cutting edges that almost reach the center of the tool. Although both strategies are already commonly used, there is a clear gap in the literature in studies that compare tool wear, surface roughness, and productivity in each case. This paper describes an experimental study comparing the milling of deep slots in AA7050-T7451 aluminum alloy, coated with a novel DLCSiO500W3.5O2 layer to minimize the aluminum adhesion to the tool, using conventional and plunge milling strategies. The main novelty of this paper is to present a broad study regarding different factors involved in machining operations and comparing two distinct strategies using a novel tool coating in the milling of aeronautical aluminum alloy. Tool wear is correlated with the vibrations of the tools in each situation, the cycle time is compared between the cases studied, and the surface roughness of the machined surfaces is analyzed. This study concludes that the cycle time of plunge milling can be about 20% less than that of conventional milling procedures, favoring economic sustainability and modifying the wear observed on the tools. Plunge milling can increase productivity, does not increase tool tip wear, and avoids damaging the side edges of the tool, which can eventually be used for final finishing operations. Therefore, it can be said that the plunge milling strategy improves economic and environmental sustainability as it uses all the cutting edges of the tools in a more balanced way, with less global wear.

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Section: Vibration Analysissupporting

confidence: 84%

Section: Vibration Analysissupporting

confidence: 84%

A Comparative Study of Different Milling Strategies on Productivity, Tool Wear, Surface Roughness, and Vibration

Silva,

Martinho,

Magalhães

et al. 2024

JMMP

View full text Add to dashboard Cite

show abstract

Comprehensive machinability assessment of Ti6Al4V alloy during drilling and helical milling using sustainable dry condition

Hiremath,

Malghan,

Bolar

et al. 2024

Int J Interact Des Manuf

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Cutting fluids are an essential requirement while machining materials like Ti6Al4V alloy exhibiting low thermal conductivity and work hardening behavior. However, the non-biodegradable nature of the oil increases carbon emissions and causes serious health concerns, thus jeopardizing sustainability. In addition, complexity increases when drilling Ti6Al4V alloy due to the temperature build-up, leading to material adhesion and accelerated tool wear. The study, therefore, investigates the utility of helical milling for creating holes in Ti6Al4V alloy. The hole-making operations were appraised considering the chip morphology, microhardness, machining temperature, tool wear, and surface roughness. The findings show that hole-making using helical milling was beneficial since it produced lower thrust force. Measured temperatures during helical milling were significantly lower than in drilling. Helically milled holes displayed superior quality holes with lower surface roughness; however, at higher productivity conditions, chatter marks were noted. The microhardness was lower near the machined surface in the case of conventional drilling, indicating material softening. In comparison, helical milled holes displayed higher microhardness very close to the edge of the hole due to work hardening. The helical milling operation produced short discontinuous chips, which are desirable while machining Ti6Al4V alloy. Furthermore, the examination of the cutting tool showed material adhesion. The severity of tool damage was significantly lower during the helical milling operation. The initial assessment indicates that helical milling is an adept process for making holes in Ti6Al4V alloy.

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Prediction of Abrasive Belt Wear Height for Screw Rotor Belt Grinding Based on BP Neural Network with Improved Skyhawk Algorithm

Pan,

Sun,

Yang

et al. 2024

Int. J. Precis. Eng. Manuf.

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Unravelling the influence of vibration on material removal and microstructure evolution in ultrasonic transversal vibration-assisted helical milling of Ti-6Al-4V holes

Cited by 21 publications

References 53 publications

A Comparative Study of Different Milling Strategies on Productivity, Tool Wear, Surface Roughness, and Vibration

A Comparative Study of Different Milling Strategies on Productivity, Tool Wear, Surface Roughness, and Vibration

Comprehensive machinability assessment of Ti6Al4V alloy during drilling and helical milling using sustainable dry condition

Prediction of Abrasive Belt Wear Height for Screw Rotor Belt Grinding Based on BP Neural Network with Improved Skyhawk Algorithm

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