Process Optimization and Wear Mechanism of Ultrasonic-assisted Milling of Titanium Alloy Based on PVD-coated Tools

doi:10.3901/JME.2025.23.344

Abstract

Abstract: In order to address the challenges which negatively impact surface quality and efficiency encountered during the machining of difficult-to machine materials titanium alloys, such as cutting heat accumulation and tool wear, the ultrasonic-assisted milling (UAM) technology based on physical vapor deposition (PVD) coated tungsten carbide tools has been proposed for efficient and high-quality machining of titanium alloys. Firstly, the vibration separation mechanism at the tool-workpiece interface in UAM is analyzed. Subsequently, the effects of process parameters, including spindle speed and ultrasonic amplitude, on the surface quality of titanium alloy TA15 are investigated, and the process parameters are optimized. Finally, a comparative analysis is conducted between conventional milling (CM) and UAM to investigate the wear mechanisms of PVD-coated Zr-based and Ti-based tools during titaniumalloy milling, as well as the influences of UAM process parameters on the surface quality of titanium alloy. The experimental results indicate that the proposed UAM based on PVD-coated tools may realize efficient and high-quality machining of titanium alloys. The optimized process parameters of UAM are determined as the spindle speed of 10 000 r/min and the ultrasonic amplitude of 3.30 μm. The wear forms of the coated tools mainly include coating peeling, crater wear on the rake face, as well as adhesion, diffusion and oxidation wear on the flank face. Additionally, ultrasonic vibration can reduce the diffusion, oxidation, abrasive wear of the tool and the micro-chipping of the cutting edge. In comparison to CM, the adoption of UAM leads to a reduction of approximately 15% in surface roughness of titanium alloy. At the same time, compared to Ti-based coated tool, the average wear volume on the flank face of the Zr-based coated tool is reduced by 18.34%. The milled surface roughness of titanium alloy is 0.082 μm, which is hardly any adhesion of titanium chips.

Key words: milling, ultrasonic vibration, titanium alloy, wear, coated tool

CLC Number:

TH161
TG580

LU Yanjun, YE Yonghui, GUAN Weifeng, CHEN Yuhan, ZHU Xueming, WU Yongbo. Process Optimization and Wear Mechanism of Ultrasonic-assisted Milling of Titanium Alloy Based on PVD-coated Tools[J]. Journal of Mechanical Engineering, 2025, 61(23): 344-360.

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