Mechanical Model and Experimental Verification for Minimum Quantity Lubrication Turning Titanium Alloy Ti-6Al-4V with Biomimetic Textured Tools Empowered by Ultrasonic

doi:10.3901/JME.260431

Abstract

Abstract: Titanium alloy is a crucial metallic material indispensable for the main structure of aircraft and engine components. In the mechanical manufacturing process of titanium alloy parts, cutting is a typical processing method. However, insufficient effective infiltration of lubricant at the interface between the tool and the workpiece during continuous turning and excessive cutting force lead to severe tool wear, which are the main bottlenecks in its machining. The turning process of ultrasonic-energized bionic texture tools with minimum quantity lubrication is expected to solve the problem of tool wear during titanium alloy cutting. Nevertheless, the material removal mechanism and mechanical behavior of the new process are still unclear. Based on this, a mechanical model for material removal in the turning process of UVT-NMQL is established. The material removal characteristics of ultrasonic parameters such as instantaneous cutting thickness, instantaneous cutting speed, instantaneous shear angle, and instantaneous tool-chip contact state are clarified. A technical route for cutting force prediction under multiple working conditions is constructed, and the influence laws of input parameters and cutting speed on the cutting force are analysed. Under four experimental conditions of dry cutting, NMQL, T-NMQL, and UVT-NMQL, the cutting forces per unit area of material removal for the titanium alloy Ti-6Al-4V material are 2 504.18 N/mm², 2 255.85 N/mm², 2 074.71 N/mm², and 803.67 N/mm², respectively. Under the UVT-NMQL condition, the prediction model and the experimental results show that a consistent trend of change. When the cutting speed increased, the cutting force increased, and the average deviation of the model is 7.46%. The prediction model of turning force for UVT-NMQL established based on the material removal mechanism can provide theoretical guidance and technical support for both the industrial and academic fields.

Key words: cutting force, minimum quantity lubrication, ultrasonic vibration, textured cutting tools, mechanical model

CLC Number:

TG506

WANG Xiaoming, LIU Jixin, YANG Min, LIU Mingzheng, ZHANG Yanbin, LI Benkai, WU Huijun, XU Yingjie, BIE Qingfeng, YIN Xianxin, HOU Yali, LI Changhe. Mechanical Model and Experimental Verification for Minimum Quantity Lubrication Turning Titanium Alloy Ti-6Al-4V with Biomimetic Textured Tools Empowered by Ultrasonic[J]. Journal of Mechanical Engineering, 2026, 62(9): 394-407.

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URL: http://www.cjmenet.com.cn/EN/10.3901/JME.260431

http://www.cjmenet.com.cn/EN/Y2026/V62/I9/394

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