Abstract
In the traditional micromilling (TMM) of Inconel718 alloy, due to the influence of material plasticity and size effect, relatively large burr will be produced. In order to hinder the burr forming in micromilling, ultrasonic vibration in feed direction is applied to the workpiece to complete vibration cutting. Combined with trajectory simulation and cutting experiment, the burr formation mechanism of TMM and ultrasonic vibration assisted micromilling (UVAMM) was studied. The results show that when the ratio of amplitude (A) to feed per tooth (ƒz) is greater than 0.5, continuous cutting changes to intermittent cutting in the vibration cutting process. The fractured area with dimples on the burr increases with the increase of amplitude. Compared with TMM, UVAMM improves chip breaking ability, facilitates the propagation of burr crack, and effectively inhibits the formation of burr. When the chip breaking condition is reached, the burr shape is usually tearing or flocculent. Under the conditions of low speed (n), large ƒz, and large A, the burr suppression is more obvious.
Highlights
Inconel718 alloy has excellent high temperature strength, high temperature oxidation resistance and corrosion resistance
In the machining process of UVAMM, ƒz and A are the most important parameters to change the formation mechanism of chip and burr, so it is very important to judge the relationship between ƒz and A by analyzing the tool tip trajectory
As the A increases from 3 to 6 μm, there are the significant intersections of tool tip trajectory between tool tip1 and tool tip2, which indicates that the chip is no longer continuous
Summary
Inconel718 alloy has excellent high temperature strength, high temperature oxidation resistance and corrosion resistance. In order to suppress the generation of burrs, some scholars have done a lot of research by optimizing processing parameters. Hajiahmadi [11] studied the influence of ap, n and ƒz on the size of the burr, and optimized the process parameters reasonably. In addition to optimizing processing parameters, burrs can be suppressed by changing cutting conditions. The technology to reduce burrs includes traditional micromilling(TMM) which will produce new burrs, laser technology which may burn the surface of the workpiece, micropeening which is only applied to higher hardness steel and ultrasonic wet peening which may lead to the longer cleaning time [17,18]. The minimization and control of burrs are the key for micromilling to improve the surface quality of the workpieces and lower the machining cost
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