Abstract
There are high cutting temperatures, large tool wear, and poor tool life in conventional machining, owing to the superior strength and low thermal conductivity of titanium alloy. In this work, ultrasonic atomization assisted turning (UAAT) of Ti6Al4V was performed with a mixed water-soluble oil-based cutting fluid, dispersed into tiny droplets by the high frequency vibration of a piezoelectric crystal. Different cutting speeds and two machining environments, dry and ultrasonic atomization assisted machining, were considered in the investigation of tool life, tool wear morphology, surface roughness, and chip morphology. In comparison with dry machining, UAAT shows lower tool wear and longer tool life due to the advantages of cooling and lubrication. Furthermore, better surface roughness, smoother chip edges, and shorter tool-chip contact length were obtained with UAAT.
Highlights
Titanium alloy has a high strength–weight ratio, good corrosion resistance, outstanding mechanical and thermal properties, and is currently one of the most widely used materials in aerospace, shipbuilding, medical, and other fields [1,2,3,4,5]
The results indicated that the mean thrust force decreased by 17%, but the surface roughness increased by 36%
Tool wear was evaluated on the basis of the wear of the tool flank
Summary
Titanium alloy has a high strength–weight ratio, good corrosion resistance, outstanding mechanical and thermal properties, and is currently one of the most widely used materials in aerospace, shipbuilding, medical, and other fields [1,2,3,4,5]. Sun et al [12] used the cutting tools of PCBN and polycrystalline diamond (PCD) in dry machining Ti6Al4V titanium alloy. They concluded that the strong diffusivity of the PCD material made the performance of the PCD tool better than that of the PCBN tool. Dry machining of titanium alloys shows high cutting temperatures, high tool wear, low tool life, poor surface quality, and a low material removal rate. Laser-assisted machining (LAM) is an effective method, which reduces the cutting resistance of the material by locally heating and softening the workpiece [13]. Experiments were performed to investigate the tool wear, surface roughness, and chip morphology in ultrasonic atomization assisted turning (UAAT) of Ti6Al4V alloy. Conventional dry machining was conducted under the same cutting conditions
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