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Analytical modelling and experimental study of surface roughness in ultrasonic elliptical vibration assisted ultra-precision cutting of Ti-6Al-4 V alloy

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Abstract

Ti-6Al-4 V alloy is growing used in the fields of aerospace, automobile and medical industries, and the requirement for machining accuracy of those parts is also increasing. However, it is difficult to achieve ultra-precision cutting of titanium alloy with traditional manufacture techniques. The ultrasonic elliptical vibration assisted cutting (UEVC) is considered the promising manufacture strategy for ultra-precision cutting of Ti-6Al-4 V alloy. Remarkably, under the ultra-precision cutting scale, the detrimental effect of vibration texture caused by UEVC process on surface roughness should not be ignored. In this paper, the theoretical analysis and experimental studies on the influence of process parameters on the surface roughness were carried out for suppressing the adverse effects of vibration texture and improving the machined surface quality. The influence of vibration amplitudes in cutting and cutting depth directions, tool edge radius, cutting speed, and feed rate on the surface roughness was clarified. An ultra-precision machined surface of Ti-6Al-4 V alloy (Ra < 30 nm) was obtained, when the optimal process parameters were adopted. The research results indicated that the use of optimal process parameters can suppress the adverse effect of vibration texture on surface roughness and simultaneously retain the technical advantages of UEVC process.

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Funding

This paper is funded by the Open Project of Key Laboratory of Conveyance Equipment (East China Jiaotong University), Ministry of Education (Grant No. KLCE2021-09), the Science and Technology Research Project of Jiangxi Provincial Department of Education (Grant No. GJJ210641), the Open Project of Henan Province Engineering Research Center of Ultrasonic Technology Application (Grant No. PXY-JXKFJJ-202101), and the Science Challenge Project of China (Grant No. TZ2018006-0202).

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Authors and Affiliations

  1. Key Laboratory of Conveyance and Equipment of Ministry of Education, East China Jiaotong University, Nanchang, 330013, People’s Republic of China

    Rongkai Tan, Fengtao Lin, Shijing Jin, Xianmin Guo & Xin Chen

  2. State Key Laboratory of Performance Monitoring and Protecting of Rail Transit Infrastructure, East China Jiaotong University, Nanchang, 330013, People’s Republic of China

    Rongkai Tan & Fengtao Lin

  3. NMPA Key Laboratory of Quality Evaluation of Traditional Chinese Patent Medicine, Jiangxi Institute for Drug Control, Nanchang, 330029, People’s Republic of China

    Rongkai Tan

  4. Center for Precision Engineering, Harbin Institute of Technology, Harbin, 150001, People’s Republic of China

    Xuesen Zhao & Tao Sun

Authors
  1. Rongkai Tan
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  2. Xuesen Zhao
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  3. Fengtao Lin
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  4. Shijing Jin
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  5. Xianmin Guo
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  6. Xin Chen
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  7. Tao Sun
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Contributions

Rongkai Tan: conceptualization, methodology, supervision, writing-review and editing. Xianmin Guo and Xin Chen: formal analysis, writing-original draft. Shijing Jin: visualization, software. Fengtao Lin: investigation, data curation. Xuesen Zhao: investigation. Tao Sun: resources.

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Correspondence to Rongkai Tan or Tao Sun.

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Tan, R., Zhao, X., Lin, F. et al. Analytical modelling and experimental study of surface roughness in ultrasonic elliptical vibration assisted ultra-precision cutting of Ti-6Al-4 V alloy. Int J Adv Manuf Technol 126, 1863–1875 (2023). https://doi.org/10.1007/s00170-023-11261-z

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