Study on ultra-precision processing of Ti-6Al-4V with different ultrasonic vibration-assisted cutting modes

Tan, Rongkai; Zhao, Xuesen; Zhang, Shuo; Zou, Xicong; Guo, Shusen; Hu, Zhenjiang; Sun, Tao

doi:10.1080/10426914.2019.1660788

Cited by 28 publications

(5 citation statements)

References 37 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Khanna et al 17 analysed the machining performance of Inconel 718 under UAT and cryogenic-applied UAT (CUAT) processes. The results showed that CUAT reduces the Ra by 14% to 25% lesser than UAT and 25% to 33% lesser than CT. Tan et al 18 studied the ultra-precision cutting of Ti6Al4V alloy using CT, UAT and ultrasonic elliptical vibration-assisted cutting (UEVC). The authors found that UEVC produced a surface finish of 39.2 nm compared to the other two cutting modes.…”

Section: Introductionmentioning

confidence: 99%

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

Umasekar

John

2023

Proceedings of the Institution of Mechanical Engineers, Part E:

View full text Add to dashboard Cite

Ultrasonic-assisted turning (UAT) is a hybrid machining method that improves difficult-to-cut materials’ machinability and surface integrity. Minimum quantity lubrication (MQL) is a cooling condition employed in metal cutting operations to improve machining performance and environmental sustainability. This article presents the experimental investigations on the effect of machining and vibration parameters and cooling conditions on the surface roughness (Ra), flank wear (Vb), and surface hardness (HV) during UAT of AISI D2 tool steel. Experiments were designed based on L36 orthogonal array. Two levels of spindle speeds, feed rates, depth of cut, and three levels of percentage intensity of ultrasonic power (PIUP) were employed, and two cooling conditions, like dry and MQL. Analysis of variance (ANOVA) was used to find the significant input parameters that affect each response. ANOVA output revealed that feed rate was the most influential factor on Ra, the PUIP is the dominant factor on HV, and spindle speed is the significant factor on Vb. Optimisation is performed to find optimal parameters as per Taguchi multi-response method. The optimal parameters are 450 rpm spindle speed, 0.05 mm/rev feed rate, 0.1 mm depth of cut, 100 PIUP and MQL cooling resulted in minimum surface roughness of 0.439 μm, maximum hardness of 283 HV and minimum flank wear of 168 μm. Flank wear morphology results showed that abrasion and chipping are the tool wear mechanism in dry UAT, whereas minor abrasion alone was found in MQL UAT compared to CT. Chip morphology study showed that UAT produced continuous spiral-type chips under both cooling conditions compared to CT. A novel design approach is implemented to design the UAT tool. Along with the UAT tool, MQL is also given to improve the machinability of D2 tool steel. This UAT tool can machine intricate metals with a critical cutting velocity of less than 75.4 m/min.

show abstract

Section: Introductionmentioning

confidence: 99%

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

Umasekar

John

2023

Proceedings of the Institution of Mechanical Engineers, Part E:

View full text Add to dashboard Cite

show abstract

“…In a study by Tan et al, 21 research was done on titanium alloy. Then, machining conditions in conventional machining (CC), vibrating linear ultrasonic cutting (ULVC), and vibrating ultrasonic elliptical cutting (UEVC) were investigated.…”

Section: Introductionmentioning

confidence: 99%

“…Moreover, using elliptical vibration in UA turning improves the machinability of Inconel 718 and reduces the BUE formation and surface roughness. In a study by Tan et al, 21 research was done on titanium alloy. Then, machining conditions in conventional machining (CC), vibrating linear ultrasonic cutting (ULVC), and vibrating ultrasonic elliptical cutting (UEVC) were investigated.…”

Section: Introductionmentioning

confidence: 99%

Correlation between residual stress and geometric tolerances in ultrasonic assisted turning

Bayat

Amini

2022

Proceedings of the Institution of Mechanical Engineers, Part B:

View full text Add to dashboard Cite

High accuracy in production parts and manufacturing quality are the requirements of production. Residual stress affects the surface quality and dimensional accuracy of manufactured parts. Production of parts with geometric tolerance, optimal residual stress, and suitable surface quality is always required by manufacturing industries. When machining parts, tensile residual stresses are created in them, which is one of the main reasons for the loss of geometric tolerances and distortion in the workpiece. This study investigated the effect of the ultrasonic-assisted vibration compared with conventional machining in various conditions of a 2024 aluminum workpiece on the surface quality, runout, straightness, and tensile residual stresses. In this article, the effects of geometric tolerance parameters, tensile residual stress, and surface roughness have been investigated simultaneously. A total of 18 experiments in different cutting speeds and feed rates in two machining states of conventional and ultrasonic vibration states were performed. The results showed that ultrasonic vibrations could be used to achieve 31% lower run out and 36% lower straightness in the parts. Also, the values of tensile residual stress in the ultrasonic vibration machining were 11% lower compared to conventional machining. Ultrasonic vibrations can also be used in most cases to achieve better surface quality, tolerance, and tensile residual stress according to machining parameters compared to conventional machining. The experimental results show that ultrasonic-assisted turning is a reliable method for machining, which can obtain lower tensile residual stress and improve the machined surface integrity and better tolerances.

show abstract

“…Titanium alloys have been considered to be typical hard-to-cut materials owing to their inherent properties such as the high chemical reactivity, high strain hardening (work hardening), low thermal conductivity and small deformation coefficient [14]. Hence, the high-quality and high-precision machining of the micro-groove on titanium alloy has always been a challenge with the conventional cutting (CC) process [15,16,17]. During the processing of a micro-groove on titanium alloy using the CC process, the generated cutting heat could not be effectively dissipated through the workpiece or chips because of the low thermal conductivity.…”

Section: Introductionmentioning

confidence: 99%

“…More remarkably, the effect of the material swelling and springback of titanium alloy was enhanced due to its low elastic modulus and thermal conductivity [16]. Furthermore, during the CC process, many surface defects such as adhered particles, a welded built-up edge (BUE) and plastic flow grooves appeared on the finished surface [15,18]. Previous studies have suggested that the high cutting temperature was the main factor that caused the formation of surface defect and the serious material swelling and springback [16,19].…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigation on Micro-Groove Manufacturing of Ti-6Al-4V Alloy by Using Ultrasonic Elliptical Vibration Assisted Cutting

et al. 2019

Self Cite

View full text Add to dashboard Cite

The micro-groove structure on the planar surface has been widely used in the tribology field for improving the lubrication performance, thereby reducing the friction coefficient and wear. However, in the conventional cutting (CC) process, the high-quality, high-precision machining of the micro-groove on titanium alloy has always been a challenge, because considerable problems including poor surface integrity and a high level of the material swelling and springback remain unresolved. In this study, the ultrasonic elliptical vibration assisted cutting (UEVC) technology was employed, which aimed to minimize the level of the material swelling and springback and improve the machining quality. A series of comparative investigations on the surface defect, surface roughness, and material swelling and springback under the CC and UEVC processes were performed. The experimental results certified that the material swelling and springback significantly reduced and the surface integrity obviously improved in the UEVC process in comparison to that in the CC process. Furthermore, for all the predetermined depths of the cut, when the TSR (the ratio of the nominal cutting speed to the peak horizontal vibration speed) was equal to one of twenty four or one of forty eight, the accuracy of the machined micro-groove depth, width and the profile radius reached satisfactorily to 98%, and the roughness values were approximately 0.1 μm. The experimental results demonstrate that the UEVC technology is a feasible method for the high-quality and high-precision processing of the micro-groove on Ti-6Al-4V alloy.

show abstract

Study on ultra-precision processing of Ti-6Al-4V with different ultrasonic vibration-assisted cutting modes

Cited by 28 publications

References 37 publications

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

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

Correlation between residual stress and geometric tolerances in ultrasonic assisted turning

Experimental Investigation on Micro-Groove Manufacturing of Ti-6Al-4V Alloy by Using Ultrasonic Elliptical Vibration Assisted Cutting

Contact Info

Product

Resources

About