Analytical model of workpiece temperature in axial ultrasonic vibration-assisted milling in-situ TiB2/7050Al MMCs

Abstract

As a new method developed for machining difficult-to-cut materials, ultrasonic vibration-assisted machining technology has received increasing attention due to its superior properties in reducing cutting temperature in recent years. However, analytical models revealing the mechanism and predicting the cutting temperature for ultrasonic vibration-assisted machining are still needed to be developed. In this paper, an analytical model was established to predict the workpiece temperature for ultrasonic vibration-assisted milling of in-situ TiB2/Al-MMCs. The heat intensity would be directly determined by the cutting force which was significantly influenced by the ultrasonic vibration motion. Meanwhile, the moving heat source theory was applied for calculating dynamic heat flux and partition ratio. Besides, material properties, tool geometry, cutting parameters and vibration parameters were taken into account for workpiece temperature modeling. Finally, the developed analytical temperature model was validated by milling experiments with and without ultrasonic vibration on in-situ TiB2/7050Al metal matrix composites. The relative errors between model prediction results and experiments were smaller than 17%, indicating that the proposed model could provide workpiece temperature prediction reliability and accuracy. Furthermore, the established-analytical model could be used not only in ultrasonic vibration-assisted milling but also in conventional milling for the metal matrix composites.

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“…The intermittent contact between the milling flute and the workpiece decreases the average cutting force as reported by Pang et al 2 during milling Titanium alloy. The UVAM also gives others benefits such as decreasing cutting temperature 3 , extending the tool life 4 , and improving roughness on the side wall 1 .…”