Experimental Study on Cutting Force and Surface Integrity of TC4 Titanium Alloy with Longitudinal Ultrasonic-Assisted Milling
Source abstract
Abstract
The ultrasonic vibration-assisted milling process was used to study the difficult-to-machine aerospace material titanium alloy TC4 and explore the milling parameters that fit the processing. Based on the orthogonal experimental method, the changes in cutting force, roughness, and surface morphology under conventional and ultrasonic-assisted milling conditions were studied, and the relationship between various processing parameters and their effects was obtained. The results showed that the cutting force was most affected by the feed per tooth and cutting depth. Adding ultrasonic vibration could change the surface texture and significantly impact roughness. By adding an appropriate amplitude of ultrasonic-assisted milling, the maximum average cutting force can be reduced by more than 20.66%, and the maximum surface roughness can be reduced by 44.23%, making the workpiece surface produce regular “sine/cosine” patterns and improving the surface quality of the workpiece. Compared with conventional milling, the deformation layer of the workpiece slightly increased under ultrasonic-assisted milling. The cutting force and surface roughness of titanium alloy TC4 under ultrasonic-assisted milling were reduced. A reasonable selection of processing parameters can further improve cutting force and other parameters, providing a reference basis for the processing of aerospace materials.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Advanced machining processes and optimization · Advanced Machining and Optimization Techniques · Additive Manufacturing Materials and Processes
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
School of Mechanical and Power Engineering, Henan Polytechnic University, Jiaozuo 454000, China
Henan Province Engineering Research Center of Ultrasonic Technology Application, Pingdingshan University, Pingdingshan 467000, China
Funding
Key R & D and Promotion Special/Tackling Key Problems in Science and Technology in Henan province · Key Scientific Research Fund of Pingdingshan University
References (43)
Show source-provided references
1. Review of ultrasonic vibration-assisted machining in advanced materials10.1016/j.ijmachtools.2020.103594 ↗
2. Bai, W., Gao, Y., and Sun, R.L. (2023). Vibration Assisted Machining: Fundamentals, Modelling and Applications, Springer.10.1007/978-981-19-9131-8 ↗
3. Zheng, L., Chen, W.Q., and Huo, D.H. (2021). Vibration Assisted Machining: Theory, Modelling and Applications, ASME Press.10.1115/1.862VAM ↗
4. Experimental analysis of cutting force reduction during ultrasonic assisted turning of Ti6Al4V10.1016/j.procir.2018.08.227 ↗
5. FEM to predict the effect of feed rate on surface roughness with cutting force during face milling of titanium alloy10.1016/j.hbrcj.2013.05.003 ↗
6. Effect of ultrasonic peening cutting on surface integrity and fatigue behavior of Ti-6Al-4 V specimens10.1016/j.jmatprotec.2019.116386 ↗
7. Progressive mapping surface integrity and multi-objective optimizing surface quality of machining Ti-6Al-4V based novel tool failure criterion10.1016/j.cirpj.2023.01.013 ↗
8. Investigations of micro-textured surface generation mechanism and tribological properties in ultrasonic vibration-assisted milling of Ti-6Al-4V10.1016/j.precisioneng.2019.04.010 ↗
9. Investigation of the effect of vibration amplitude on the surface integrity in high-speed rotary ultrasonic elliptical machining for side milling of Ti-6Al-4V10.3901/JME.2019.11.215 ↗
10. Effects of rotary ultrasonic elliptical machining for side milling on the surface integrity of Ti-6Al-4 V10.1007/s00170-018-2847-3 ↗
11. Kurpiel, S., Zagórski, K., Cieślik, J., and Skrzypkowski, K. (2023). Investigation of selected surface topography parameters and deformation during milling of vertical thin-walled structures from titanium alloy Ti6Al4V. Materials, 16.10.3390/ma16083182 ↗
12. Improvement of Ti-6Al-4V surface integrity through the use of high-speed ultrasonic vibration cutting10.1016/j.triboint.2021.107025 ↗
13. Effect of cutting speed on chip shape and shear band of titanium alloy
14. Experimental study on surface residual stress of titanium alloy curved thin-walled parts by ultrasonic longitudinal-torsional composite milling10.1007/s00170-021-07234-9 ↗
15. Wei, W.H. (2010). Fundamental Research on Machinability of Titanium Alloy by Thermo Hydrogen Treatment. [Master Thesis, Nanjing University of Aeronautics and Astronautics].
16. Surface morphology characteristics and effectiveness analysis of ultrasonic longitudinal torsion assisted milling of titanium alloys
17. Investigation of cutting modes effect on cutting force while machining titanium alloy BT6 (Russian State Standard GOST 19807-91)10.1016/j.matpr.2020.08.088 ↗
18. Development of experimental study on high-speed cutting of titanium alloys
19. Investigation of cutting temperature, cutting force and surface roughness using multi-objective optimization for turning of Ti-6Al-4V(ELI)10.1016/j.matpr.2021.08.285 ↗
20. Enhancement of machinability and surface quality of Ti-6Al-4V by longitudinal ultrasonic vibration-assisted milling under dry conditions10.1016/j.measurement.2021.110324 ↗
21. Research on the characteristics of cutting force signal and chip in ultrasonic vibration-assisted milling of titanium alloys10.3901/JME.2019.07.207 ↗
22. Enhanced dry machinability of TC4 titanium alloy by longitudinal-bending hybrid ultrasonic vibration-assisted milling10.1016/j.jclepro.2022.134866 ↗
23. Finite element analysis on prediction of tool wear in milling titanium10.3901/JME.2016.05.193 ↗
24. Wear mechanism of tool in milling high-strength titanium alloy TC18
25. Sustainable production of dry-ultra-precision machining of Ti-6Al-4V alloy using PCD tool under ultrasonic elliptical vibration-assisted cutting10.1016/j.jclepro.2019.119254 ↗
26. Cutting force model of longitudinal-torsional ultrasonic-assisted millingTi-6Al-4V based on tool flank wear10.1016/j.jmatprotec.2021.117042 ↗
27. Experimental study of tool wear and its effects on cutting process of ultrasonic-assisted milling of Ti6Al4V10.1007/s00170-020-05593-3 ↗
28. Study on tool wear in longitudinal-torsional composite ultrasonic vibration–assisted drilling of Ti-6Al-4V alloy10.1007/s00170-021-06759-3 ↗
29. Surface and sub-surface analysis of rotary ultrasonic elliptical end milling of Ti-6Al-4V10.1016/j.matdes.2020.108658 ↗
30. Evauation on Materials and Technics of Aviation Engine
31. Surface integrity in metal machining–Part II: Functional performance10.1016/j.ijmachtools.2021.103718 ↗
32. Microstructural evolution of Ti6Al4V in ultrasonically assisted cutting: Numerical modelling and experimental analysis10.1016/j.ultras.2017.03.005 ↗
33. Sub-surface and surface analysis of high speed machined Ti-6Al-4V alloy10.1016/j.msea.2009.12.018 ↗
34. Subsurface damage and burr improvements of aramid fiber reinforced plastics by using longitudinal-torsional ultrasonic vibration milling10.1016/j.jmatprotec.2021.117265 ↗
35. Modeling Cutting Force in Micro-Milling of Ti-6Al-4V Titanium Alloy10.1016/j.proeng.2015.12.021 ↗
36. Experiment of Machining Induced Residual Stress in Longitudinal Torsional Ultrasonic Assisted Milling of Ti-6Al-4V
37. Study on Surface Roughness of High Speed Milling of TC4 Titanium Alloy
38. Huang, B.Y. (2006). Chinese Materials Engineering Ceremony (Non-Ferrous Metal Materials Engineering), Chemical Industry Press.
39. Zhao, Y.Q., Xin, S.W., Chen, Y.N., and Mao, X.N. (2017). New Alloy Material-Titanium Alloy, China Railway Publishing House.
40. Grzesik, W. (2017). Advanced Machining Processes of Metallic Materials: Theory, Modelling, and Applications, Elsevier B.V. Press. [2nd ed.].10.1016/B978-0-444-63711-6.00015-6 ↗
41. Xie, W.B. (2022). Study on Cutting Force and Surface Integrity of TC18 Titanium Alloy by Longitudinal-Torsional Ultrasonic Vibration-Assisted Milling. [Master Thesis, Chongqing University].10.21203/rs.3.rs-630708/v1 ↗
42. Cheng, K., and Huo, D.H. (2013). Micro-Cutting Fundamentals and Applications, John Wiley & Sons Press.10.1002/9781118536605 ↗
43. The Theoretical Analysis of Orthogonal Test Designs