Abstract
In recent years, as a new method developed for machining difficult-to-cut materials, ultrasonic vibration-assisted machining technology has been attracting more and more attentions due to its superior properties in reducing cutting temperature. However, analytical models revealing the mechanism and predicting the cutting temperature for ultrasonic vibration-assisted machining are still needed to be developed. In this paper, an analytical model was established to predict the workpiece temperature for ultrasonic vibration-assisted milling of in situ TiB2/Al MMCs. The heat intensity would be directly determined by the cutting force which was significantly influenced by the ultrasonic vibration motion. Meanwhile, the moving heat source theory was applied for calculating dynamic heat flux and partition ratio. Besides, material properties, tool geometry, cutting parameters, and vibration parameters were taken into account for workpiece temperature modeling. Finally, the developed analytical temperature model was validated by milling experiments with and without ultrasonic vibration on in situ TiB2/7050Al metal matrix composites. The relative errors between model prediction results and experiments were smaller than 17%, indicating that the proposed model could provide workpiece temperature prediction reliably and accurately. Furthermore, the established analytical model could be used not only in ultrasonic vibration-assisted milling but also in conventional milling for the metal matrix composites.
Highlights
The heat generated in metal cutting process resulting in cutting temperature rising is one of the main physical phenomena, which would have a direct significant effect on the surface quality, residual stress and machined defects in metal removal processes
The proposed cutting temperature model for ultrasonic vibration-assisted milling is validated by a series of experiments on in-situ TiB2/7050Al MMCs and the results of validation are shown in Table 5 and Fig. 7
It could be found that temperature rising ratio decreases with cutting speed and feed rate increasing while increasing obviously with cutting depth
Summary
The heat generated in metal cutting process resulting in cutting temperature rising is one of the main physical phenomena, which would have a direct significant effect on the surface quality, residual stress and machined defects in metal removal processes. Compared with conventional machining method, the motion of cutting tool or workpiece and the material removal process is changed in ultrasonic vibration-assisted machining, which would result in great difference in cutting temperature generation and its effects on machining quality. Verma et al [19] proposed an analytical model for temperature rise in workpiece during ultrasonic vibration-assisted milling (UVM). It considered the effect of acoustic softening and intermittent cutting based on Jaeger’s moving heat source theory. It is quite necessary and important to perform temperature modeling investigation for ultrasonic vibrationassisted milling in-situ TiB2/7050Al composites for fully and comprehensively understanding the influence of ultrasonic vibration on machining quality. The proposed model is validated by a series of milling experiments with and without ultrasonic vibration on in-situ TiB2/7050Al composites
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