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Residual stress prediction in axial ultrasonic vibration–assisted milling in situ TiB2/7050Al MMCs

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Abstract

As a new method developed for machining difficult-to-cut materials, ultrasonic vibration–assisted machining technology not only could be effective in reducing cutting force and temperature but also could be significant in obtaining residual compressive stress. Especially, residual compressive stress is essential to realize anti-fatigue manufacturing for components. However, in recent years, research on residual stresses of ultrasonic vibration–assisted machining mainly focuses on experimental and finite element analysis methods. In this paper, an analytical model was established by considering the effect of ultrasonic vibration to predict residual stresses and reveal the mechanism for UVM of in situ TiB2/Al-MMCs. And a series of experiments were conducted to verify the residual stress model proposed and analyze the effect of ultrasonic vibration and cutting parameters on the surface residual stress. The results show that the predicted residual stresses are in good agreement with measured residual stress. Cutting parameters have a significant effect on the surface residual stress by influencing cutting force and cutting temperature. Residual compressive stresses could be achieved in both UVM and conventional milling, and residual compressive stresses in the former are larger than that in the latter. With cutting speed and cutting depth increasing, the relative increase ratio between UVM, and CM decreased gradually, while with feed rate increasing, it increased first and then decreased slightly.

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Change history

  • 07 August 2022

    Springer Nature’s version of this paper was updated to remove the e-mail address of the co-author in the paper.

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Acknowledgements

Many thanks to the ultrasonic vibration equipment support from Xi’an Chao Ke Neng Ultrasonic Technology Research Institute Co., Ltd.

Funding

This work is sponsored by National Science and Technology Major Project (Grant No. 2017-VII-0015–0111).

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Authors and Affiliations

  1. Key Laboratory of High Performance Manufacturing for Aero Engine, Ministry of Industry and Information Technology, School of Mechanical Engineering, Northwestern Polytechnical University, Xi’an, 710072, Shaanxi, People’s Republic of China

    Xiaofen Liu, Wenhu Wang, Yifeng Xiong & Chenwei Shan

  2. Engineering Research Center of Advanced Manufacturing Technology for Aero Engine, Ministry of Education, School of Mechanical Engineering, Northwestern Polytechnical University, Xi’an, 710072, Shaanxi, People’s Republic of China

    Xiaofen Liu, Wenhu Wang, Yifeng Xiong & Chenwei Shan

  3. School of Mechanical Engineering, Sichuan University, Chengdu, 610065, Sichuan, People’s Republic of China

    Ruisong Jiang

Authors
  1. Xiaofen Liu
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  2. Wenhu Wang
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  3. Ruisong Jiang
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  4. Yifeng Xiong
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  5. Chenwei Shan
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Contributions

Xiaofen Liu: the guidance and planning of the overall thinking, optimized and guided the experimental process, performed data measurement and analysis, wrote the first draft, and revised the contents of the first draft. Wenhu Wang: provided financial support for materials and equipment, supervision, and reviewing the first draft. Ruisong Jiang: checking and reviewing the first draft. Yifeng Xiong: responsible for the planning of the overall thinking, experimental process, and data analysis, and revised and reviewed the first draft. Chenwei Shan: funding acquisition and financial support. All the authors read and approved the final manuscript.

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Correspondence to Yifeng Xiong.

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Liu, X., Wang, W., Jiang, R. et al. Residual stress prediction in axial ultrasonic vibration–assisted milling in situ TiB2/7050Al MMCs. Int J Adv Manuf Technol 121, 7591–7606 (2022). https://doi.org/10.1007/s00170-022-09845-2

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  • DOI: https://doi.org/10.1007/s00170-022-09845-2

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