Effect of Separation-contact on the Processing Characteristics of Ultrasonic Vibration-assisted Milling of Titanium Alloy

doi:10.3901/JME.2024.09.097

Abstract

Abstract: The separation-contact in ultrasonic vibration milling will affect the high-efficiency and high-quality machining of titanium alloys. To further understand the influence of separation-contact on ultrasonic vibration-assisted milling, the milling models of contact rate and average cut thickness ratio are established, and the discrimination criterion of the ultrasonic action based on the average cut thickness ratio is proposed. By carrying out milling experiments, the mechanism of contact rate and average cut thickness ratio in periodic and continuous contact ultrasonic milling is discussed. The effect of milling and ultrasonic parameters on the tool wear of titanium alloy is investigated. The results show that the separation effect and the average thickness effect can improve the machining quality compared with traditional machining in longitudinal ultrasonic vibration-assisted milling of titanium alloy. In periodic contact milling, the separation effect caused by intermittent cutting of the cutter-workpiece is the main factor in reducing the force and improving the surface quality. In continuous contact milling (contact rate is 1), the average cutting thickness effect caused by the decrease of the average cutting thickness per unit period can reduce the force and improve the surface quality within a certain range. There is a critical cutting speed value of Ti-6Al-4V titanium alloy, which is about 42 m/min. A reasonable combination of spindle speed and ultrasonic amplitude can change the cutting speed to prevent tool wear. This plays an important role in the high-efficiency and high-quality machining and process control of titanium alloys.

Key words: contact rate, average cut thickness ratio, ultrasonic vibration milling, titanium alloy, processing characteristics

CLC Number:

ZHOU Jingguo, ZHANG Yuhang, SUI Tianyi, XING Denghai, DONG Baokun, FU Qingyu, FU Junfan, LIN Bin. Effect of Separation-contact on the Processing Characteristics of Ultrasonic Vibration-assisted Milling of Titanium Alloy[J]. Journal of Mechanical Engineering, 2024, 60(9): 97-113.

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