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Surface integrity investigation into longitudinal-torsional ultrasonic vibration side milling for a TC18 titanium alloy—part I: the effects of cutting speed on cutting force and surface integrity

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Abstract

This paper presents the results of an experimental investigation into the effects of cutting speed on cutting force and surface integrity during which experiments for conventional milling and longitudinal-torsional ultrasonic vibration-assisted milling for machining of a TC18 alloy were performed. Through an analysis of tool-workpiece kinematic characteristics, several advantages of torsional vibration cutting in the non-separated cutting area are illustrated, including variable cutting thickness, variable-front-angle cutting, and chip pulling by the cutter. The cutting force, surface quality, residual stress, and microstructure of the cutting surface were studied in detail during conventional milling and longitudinal-torsional ultrasonic vibration-assisted milling processes at different rotational speeds. The experimental results show that the average radial cutting force and the surface residual compressive stress both decreased with an increase in cutting speed. During the process of torsional vibration milling, the surface roughness increased with an increase in cutting speed before the rotational speed reached the critical speed (1107 rpm) of torsional vibration cutting without separation. After the critical speed was reached, the surface roughness decreased with an increase in cutting speed. Compared with conventional milling, the cutting force and surface roughness of longitudinal-torsional ultrasonic vibration-assisted milling are reduced by 16.05% and 45.65%, respectively. Then, the surface residual compressive stress can be increased by 24.35%. In addition, for both milling processes, the deformation layer thickness increased with an increase in rotational speed, and when the cutting speed is 1400 rpm, the depth of plastic deformation of the vibration milling sample can reach about 7.5 μm. When the rotational speed was greater than 1100 rpm, the grain was significantly elongated and refined along the cutting direction.

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Funding

This work was supported by the Research Fund for High-Level Talents of Pingdingshan University (grant numbers PXY-BSQD-202014), the National Project Cultivation Fund of Pingdingshan University (grant numbers PXY-PYJJ-202105), the Key Research Project of Institutions of Higher Education in Henan Province (grant numbers 21A430029), and Henan Province Science and Technology Equipment Key Project (grant numbers 212102210349).

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Authors and Affiliations

  1. State Key Laboratory of Mechanical Transmissions, Chongqing University, Chongqing, 400044, China

    Weibo Xie & Jian Wang

  2. Henan Engineering Research Center for Ultrasonic Technology and Application, Pingdingshan University, Pingdingshan, 467000, China

    Weibo Xie, Bo Zhao, Erbo Liu, Yongbo Chai, Xikui Wang, Liquan Yang & Guangxi Li

  3. School of Mechanical and Power Engineering, Henan Polytechnic University, Jiaozuo, 454150, China

    Bo Zhao

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  1. Weibo Xie
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Contributions

Supervision was conducted by Jian Wang and Bo Zhao. Conceptualization was performed by Weibo Xie and Erbo Liu. Visualization was conducted by Weibo Xie. Writing of the original draft was done by Weibo Xie. Data curation was performed by Weibo Xie and Yongbo Chai. Review and editing were conducted by Xikui Wang and Liquan Yang. Funding was acquired by Xikui Wang, Guangxi Li, and Jian Wang.

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Correspondence to Guangxi Li or Jian Wang.

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Xie, W., Zhao, B., Liu, E. et al. Surface integrity investigation into longitudinal-torsional ultrasonic vibration side milling for a TC18 titanium alloy—part I: the effects of cutting speed on cutting force and surface integrity. Int J Adv Manuf Technol 120, 2701–2713 (2022). https://doi.org/10.1007/s00170-022-08874-1

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