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Burr formation mechanism and experimental research in longitudinal-torsional ultrasonic-assisted milling Ti-6Al-4 V

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Abstract

Titanium alloy milling is prone to burrs at the edges of the workpiece, which can negatively affect surface integrity and dimensional accuracy, and even lead to part scrap. Ultrasonic vibration–assisted milling technology can effectively inhibit burr generation and improve machining quality. However, the research of ultrasonic vibration–assisted milling on burr inhibition is not clear, so this paper establishes a mathematical model of ultrasonic vibration vertical milling titanium alloy top burr size based on the chip deformation process and specifically analyses the effect of ultrasonic machining parameters on burr through experiments. The experimental results show that the depth of cut has the greatest influence on the burr size, and the ultrasonic vibration has the second greatest influence on the burr. The cutting force and the burr size on both sides of the groove show a trend of “decrease and then increase” with the increase of ultrasonic amplitude. When the ultrasonic amplitude was 3 µm, the cutting forces Fx and Fy were reduced by 34.42% and 31.36%, respectively, and the heights and widths of the burrs on the up milling side and on the down milling side were reduced by 75.49%, 44.33% and 89.16%, 47.82%, respectively, when comparing with no ultrasonic machining. The longitudinal-torsional ultrasonic vibration converted the large piled-up, rolled-up, and serrated burrs into intermittent, small-sized flocculent burrs, which significantly improved the burr morphology and weakened the serrated characteristics of the chips.

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Funding

This research was funded by the National Natural Science Foundation of China project “Research on Subsurface Damage Mechanism of High-speed Multidimensional Ultrasound Machining of Ceramic Matrix Composites” (Project Code: 52005164), the Henan Polytechnic University Doctoral Program Fund (B2016-27) “Research on Vehicle Condition Monitoring and Fault Diagnosis Based on Optimized Support Vector Machine”, and the Henan Polytechnic University Doctoral Program Fund (B2012-105).

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

    Wenbin Song, Mingli Zhao, Junming Zhu, Boxi Xue & Hao Wang

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  1. Wenbin Song
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Correspondence to Mingli Zhao.

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Song, W., Zhao, M., Zhu, J. et al. Burr formation mechanism and experimental research in longitudinal-torsional ultrasonic-assisted milling Ti-6Al-4 V. Int J Adv Manuf Technol 132, 2315–2331 (2024). https://doi.org/10.1007/s00170-024-13494-y

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