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A nonuniform moving heat source model for temperature simulation in ultrasonic-assisted cutting of titanium alloys

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Abstract

The ultrasonic-assisted machining (UAM) technique has been widely used in machining of difficult-to-cut materials for its well comprehensive performance, especially in the mechanical and thermal aspects. In this paper, a nonuniform moving heat source model is proposed to analyze the heat transfer problem during ultrasonic vibration-assisted machining of Ti6Al4V. The influences of ultrasonic vibration amplitude and frequency on temperature distribution are discussed in detail. Two main characteristics are observed according to the temperature contours caused by the ultrasonic-assisted machining: one is that the equivalent heat source center tends to move backward the tool rake face, and the other is that the temperature gradients in cutting direction and depth direction are inconsistent. For further study, the temperature variation with respect to vibration parameters near the shear plane and machined surface is calculated. Results show that the increase of vibration amplitude and frequency can reduce the temperature near the shear plane due to a large temperature gradient. Besides, a large vibration amplitude can obtain a low temperature on the machined surface while the increased vibration frequency results in a higher surface temperature after machining. The research can be used to provide guidance for improving the quality and efficiency of difficult-to-cut material machining.

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Funding

The authors would like to deeply appreciate the support from the National Natural Science Foundation of China (51601100, 11672141, 11572118, and 11402128), the Programs Supported by Ningbo Natural Science Foundation (2017A610092), the Hunan Provincial Science Fund for Distinguished Young Scholars (2015JJ1006), the Fok Ying-Tong Education Foundation, China (141005), and the K. C. Wong Magna Fund administered by Ningbo University.

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Authors and Affiliations

  1. School of Mechanical Engineering and Mechanics, Ningbo University, Ningbo, 315211, People’s Republic of China

    Jianbin Chen, Menghui Xu, Chao Xie & Jianke Du

  2. College of Mechanical Engineering, Guizhou University, Guiyang, 550025, People’s Republic of China

    Houfu Dai

  3. State Key Laboratory of Advanced Design and Manufacturing for Vehicle Body, Hunan University, Changsha, 410082, People’s Republic of China

    Qihong Fang

Authors
  1. Jianbin Chen
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  2. Menghui Xu
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  3. Chao Xie
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  4. Jianke Du
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  5. Houfu Dai
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  6. Qihong Fang
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Correspondence to Jianbin Chen or Qihong Fang.

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Chen, J., Xu, M., Xie, C. et al. A nonuniform moving heat source model for temperature simulation in ultrasonic-assisted cutting of titanium alloys. Int J Adv Manuf Technol 97, 3009–3021 (2018). https://doi.org/10.1007/s00170-018-2174-8

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  • DOI: https://doi.org/10.1007/s00170-018-2174-8

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