Abstract
Ti6Al4V alloys are difficult-to-cut materials that have extensive applications in the automotive and aerospace industry. A great deal of effort has been made to develop and improve the machining operations of Ti6Al4V alloys. This paper presents an experimental study that systematically analyzes the effects of the machining conditions (ultrasonic power, feed rate, spindle speed, and tool diameter) on the performance parameters (cutting force, tool wear, overcut error, and cylindricity error), while drilling high precision holes on the workpiece made of Ti6Al4V alloys using rotary ultrasonic machining (RUM). Numerical results were obtained by conducting experiments following the design of an experiment procedure. The effects of the machining conditions on each performance parameter have been determined by constructing a set of possibility distributions (i.e., trapezoidal fuzzy numbers) from the experimental data. A possibility distribution is a probability-distribution-neural representation of uncertainty, and is effective in quantifying the uncertainty underlying physical quantities when there is a limited number of data points which is the case here. Lastly, the optimal machining conditions have been identified using these possibility distributions.
Highlights
Ti6Al4V is an important alloy material extensively utilized in many engineering industries such as spacecraft, aircraft, military and medical prosthesis
(1) This study investigated the effect of the machining conditions on the performance parameters
(1) This study investigated the effect of the machining conditions on the performance parameters for drilling high precision holes in Ti6Al4V using rotary ultrasonic machining
Summary
Ti6Al4V is an important alloy material extensively utilized in many engineering industries such as spacecraft, aircraft, military and medical prosthesis. It is observed that in reported studies, the performance of the RUM machining process has been evaluated in terms of cutting force, material removal rate, exit chip size, temperature generation and tool wear. No work has been reported to study the effect of RUM machining parameters on the performance parameters of cutting force, tool wear, and production inaccuracies—simultaneously for drilling holes in Ti6Al4V—using a systematically designed experimental approach. The main aim of the current study is to systematically present the effects of the machining conditions (ultrasonic power, feed rate, spindle speed and tool diameter) on the performance parameters (cutting force, tool wear, overcut error and cylindricity error) by building a set of possibility distributions (i.e., trapezoidal fuzzy numbers). The optimal cutting conditions are identified using the possibility distributions
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