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Abstract
Axial ultrasonic vibration-assisted cutting (AUVC) has been proved to have better machining performance compared with conventional cutting methods; however, the effect of numerous and complex influencing factors on machining performance has not been clearly revealed, and a recommended combination of cutting conditions has not been proposed yet, especially for difficult-to-machine material such as Ti6Al4V alloy. This paper focuses on the experimental and theoretical investigation into Ti6Al4V machining performance with AUVC method. First, a retrospective of the separation characteristics of AUVC is provided, and the variable parameter cutting characteristics are demonstrated. The influencing factors on machining performance are classified into four categories: machining parameters, vibration parameters, tool choice, and cooling conditions. The relationship between these factors in terms of their effect on machining performance is established theoretically. Then, it describes experiments to determine the influence of these factors on cutting force, tool life, and surface roughness. For absolute influence, the orders for cutting force, tool life, and surface roughness are respectively cutting depth > amplitude > feed rate > rotation speed, rotation speed > feed rate > amplitude > cutting depth, and feed rate > amplitude > cutting depth > rotation speed. However, for relative influence, the order is unified as amplitude > feed rate > rotation speed > cutting depth. Finally, it suggests a smaller feed rate, larger amplitude, moderate rotation speed, and smaller cutting depth in addition to a WC tool coated with TiAlN and used under HPC cooling condition for optimal performance of AUVC. This recommendation is based on the theoretical analysis and experimental results of cutting force, surface roughness, and tool life.
Highlights
Saoubi et al [1] reported that Ti6Al4V alloy has attracted tremendous attention and been extensively applied for structural components in aerospace industries due to its excellent strength to weight ratio, toughness at high temperature, and corrosion resistance
Different factors which we considered for different characterizations of machining performance in AUVC were: Cutting force: cutting depth ap, rotation speed n, feed rate f, amplitude A and tool material;
It can be seen that when the rotation speed increased within a range of 12002400r/min, the main cutting force and feed resistance force for both AUVC and conventional cutting (CC) did not change significantly
Summary
Saoubi et al [1] reported that Ti6Al4V alloy has attracted tremendous attention and been extensively applied for structural components in aerospace industries due to its excellent strength to weight ratio, toughness at high temperature, and corrosion resistance. Chen et al [6] developed an ultrasonic vibration helical milling process for machining of Ti6Al4V alloy and reported the axial cutting force reduction up to 64% and improvement of surface roughness and compressive residual stress. The influence of the cutting parameters (rotation speed, feed rate, and cutting depth), vibration parameters (frequency and amplitude), tool materials (WC and CBN) and cooling conditions (dry, fluid, and HPC) on cutting performance (cutting force, tool life, and surface roughness) has not been studied systematically and the relationships among the relevant parameters in the machining process have not been clarified. This paper focuses on further experimental and theoretical investigation into cutting performance in the AUVC process for Ti6Al4V machining, with different cutting parameters, vibration parameters, tool materials, and cooling conditions.
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