Theoretical and experimental investigation into the machining performance in axial ultrasonic vibration-assisted cutting of Ti6Al4V

Abstract

Axial ultrasonic vibration-assisted cutting (AUVC) has proved to have better machining performance compared with conventional cutting methods; however, the effect of numerous and complex influencing factors on machining performance has not been clearly revealed and a recommended combination of cutting conditions has not been proposed yet, especially for difficult-to-machine material such as Ti6Al4V alloy. This paper focuses on experimental and theoretical investigation into machining performance when cutting Ti6Al4V with the AUVC method. First, a retrospective of the separation characteristics of AUVC is provided and the variable parameter cutting characteristics are demonstrated. We classify the influencing factors on machining performance into four categories: machining parameters, vibration parameters, tool choice, and cooling conditions. The relationship between these factors in terms of their effect on machining performance is established theoretically. Then, it describes experiments to determine the influence of these factors on cutting force, tool life, and surface roughness. For absolute influence, the orders for cutting force, tool life, and surface roughness are respectively cutting depth > amplitude > feed rate > rotation speed, rotation speed > feed rate > amplitude > cutting depth, and feed rate > amplitude > cutting depth > rotation speed. However, for relative influence, the order is unified as: amplitude > feed rate > rotation speed > cutting depth. Finally, it suggests a smaller feed rate, larger amplitude, moderate rotation speed, and smaller cutting depth in addition to a WC tool coated with TiAlN and used under HPC cooling condition for optimal performance of AUVC. This recommendation is based on the theoretical analysis and experimental results of cutting force, surface roughness, and tool life.

Investigation of the equivalent circuit and performance of an ultrasonic transducer under a force load

“…Ultrasonic processing technology has the advantages of reducing cutting forces and heat, decreasing tool wear, optimizing chip morphology, improving surface quality, reducing subsurface damage, improving machining efficiency, etc. It has been widely applied to titanium alloys [1][2][3][4], high-temperature alloys [5][6][7][8], semiconductor wafers [9][10][11][12], engineering ceramics [13][14][15], ceramic matrix * Author to whom any correspondence should be addressed. composites [16,17], and honeycomb composites [18][19][20][21] and other difficult-to-process materials.…”

Experimental Study on the Roundness of Deep Holes in 7075 Aluminum Alloy Parts by Two-Dimensional Ultrasonic Elliptical Vibration Boring

“…In comparison with traditional boring methods, ultrasonic elliptical vibration boring demonstrates significant reductions in boring forces, surface roughness, chip length, and boring bar vibrations. Sui et al [32,33] explored the application of the axial ultrasonic-vibration-assisted boring (AUVB) method for machining deep holes with a very large aspect ratio (greater than 4) in Ti20Al6V aviation materials. Their findings indicate that the AUVB method effectively reduces aperture errors by 50%, limits vibration amplitudes to 20-25%, and lowers the overall surface roughness of the workpiece to below 0.8 µm.…”