Abstract
In this study, we propose a longitudinal-torsion ultrasonic-assisted milling (LTUM) machining method for difficult-to-cut materials—such as titanium alloy—in order to realize anti-fatigue manufacturing. In addition, a theoretical prediction model of cutting force is established. To achieve this, we used the cutting edge trajectory of LTUM to reveal the difference in trajectory between LTUM and traditional milling (TM). Then, an undeformed chip thickness (UCT) model of LTUM was constructed. From this, the cutting force model was able to be established. A series of experiments were subsequently carried out to verify this LTUM cutting force model. Based on the established model, the influence of several parameters on cutting force was analyzed. The results showed that the established theoretical model of cutting force was in agreement with the experimental results, and that, compared to TM, the cutting force was lower in LTUM. Specifically, the cutting force in the feed direction, Fx, decreased by 24.8%, while the cutting force in the width of cut direction Fy, decreased by 29.9%.
Highlights
Titanium alloy has a number of excellent properties, such as corrosion resistance, high strength and good heat resistance, and is widely used in medical, aerospace and other fields [1]
The experimental equipment was composed of a Kistler dynamometer system (9257B, Winterthur, Switzerland), a self-developed wireless transmission longitudinal-torsion ultrasonic vibration assisted milling system, a high-speed photography camera and a computer
In order to verify the established cutting force model, the calculated cutting force result was compared with the experimental result
Summary
Titanium alloy has a number of excellent properties, such as corrosion resistance, high strength and good heat resistance, and is widely used in medical, aerospace and other fields [1]. It is considered a typical difficult-to-cut material due to its chemical, physical and mechanical properties; for instance, the cutting temperature and cutting force is high, the friction force is large, and tool wear is serious [2,3]. Compared with traditional cutting technologies, such as turning, grinding and milling, ultrasonic machining technology has obvious technological advantages, including a small cutting force, low cutting temperature, high surface quality and high machining precision [6,7,8]
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