Abstract
The material swelling effect in single point diamond turning (SPDT) causes ragged materials on a machined surface which slows down the movements of tool tip vibration, and acts as a simple impacted pendulum system with a damping effect and displays a single twin peak in fast Fourier transform (FFT). Due to the low elastic modulus and low thermal conductivity of titanium alloys, the material swelling effect of titanium alloys in SPDT is much more serious than that of traditional metals. For this reason, the tool tip vibration in SPDT of titanium alloys is expected to be different from previous reports. In this study, apart from the demonstration of the original single twin peak induced from the material swelling effect by the main cutting motion, we reported recently that there exists another twin peak induced by secondary material swelling arising from the movement of tool tip vibration in the SPDT of titanium alloys. The additional twin peak was located at the right side of the original twin peak in FFT, displaying two twin peaks in the frequency domain of cutting force and suggesting the existence of another tool tip vibration system with a new damping factor in the SPDT of titanium alloys. Combining the effects of primary and secondary material swelling, the new dynamic model with the modified damping factor of tool tip vibration system are developed, which surface roughness of the machined titanium alloys in SPDT was predicted in higher accuracy by using the new model. The FFT of cutting force, surface roughness, and surface profile were provided in this article for the experimental validations.
Highlights
Ti–6Al–4V titanium alloys are widely applied into aircraft and medical industries due to their excellent physical properties such as high mechanical strength, light-weight, and good corrosion resistance
Wang et al [23] provided the new points on an appearance of twin peaks in fast Fourier transform (FFT), they suggested that plastically deformed materials induced from material swelling should be treated as a damping factor, which the ragged surfaces caused by material swelling added the damping effect on the tool tip vibration of the single point diamond turning (SPDT) system
The FFTs of cutting force generated in SPDT of titanium alloys at different feed-rates were investigated in detail, we discovered that an additional twin peak displayed next to the original twin peak under SPDT at all ranges of feed-rate
Summary
Ti–6Al–4V titanium alloys are widely applied into aircraft and medical industries due to their excellent physical properties such as high mechanical strength, light-weight, and good corrosion resistance. Low elastic modulus and high level of material swelling generate a large volume of ragged materials on the machined surface, and the ragged materials act as major barriers for tool tip movements, inducing a process damping effect to the tool tip vibration at a tool/work-piece interface. Wang et al [23] provided the new points on an appearance of twin peaks in FFT, they suggested that plastically deformed materials induced from material swelling should be treated as a damping factor, which the ragged surfaces caused by material swelling added the damping effect on the tool tip vibration of the SPDT system. Titanium alloys are low elastic modulus materials, even small exertion forces induced from the tool tip vibration enable the inducing of secondary material swelling (SMS), causing another damping process and another tool tip vibration system in a SPDT process. The pattern of new twin peak in FFT was similar to the original twin peak generated by the tool tip vibration in the main cutting motion, suggesting the existence of another tool tip vibration system
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