Abstract
Titanium alloy and its thin-walled structures are widely used in the aerospace field. Aiming at the processing chatter and difficult-to-machine problem of titanium alloy thin-walled workpieces, rotary ultrasonic milling technology (RUM) is employed to restrict machining vibration in this paper. Firstly, for describing its dynamic characteristics, the titanium alloy web with low stiffness is equivalent to a mass-spring-damping system with three degrees of freedom. Then, a novel stability analysis method is proposed for RUM thin-walled workpiece (RUM-tww) through defining an ultrasonic function angle. Furthermore, RUM-tww stability lobe diagrams (SLDs) are achieved based on the semi-discrete method (SDM). The simulation results show that the milling stability of titanium alloy webs is improved effectively under the effect of ultrasonic vibration energy. Compared with conventional milling thin-walled workpiece (CM-tww), the stability region is increased by 80.32% within the spindle speed from 1000 to 5000r/min. Finally, the milling experiments are carried out to verify the validity and rationality of SLDs via analyzing chatter marks, cutter marks, and flatness on the machined surface. The experimental results are in good agreement with the theoretical prediction.
Similar content being viewed by others
Data availability
All data generated or analyzed during this study are included in this published article.
Code availability
Not applicable
References
Dhuria GK, Singh R, Batish A (2011) Ultrasonic machining of titanium and its alloys: a state of art review and future prospective. Int J MMM 10(4):326–355
Ding X, Chen TT, Yang YF, Li L (2016) Process optimization for milling deformation control of titanium alloy thin-walled web. Mater Sci Forum 836-837:147–154
Sun LJ, Zheng K, Liao WH, Liu JS, Feng JD, Dong S (2020) Investigation on chatter stability of robotic rotary ultrasonic milling. Rob Comput Inter Manuf 63:101911
Singh KK, Kartik V, Singh R (2018) Stability modeling with dynamic run-out in high speed micromilling of Ti6Al4V. Int J Mech Sci 150:677–690
Yue CX, Gao HN, Liu XL, Liang SY, Wang LH (2019) A review of chatter vibration research in milling. Chin J Aeronaut 32(2):215–242
Altintas Y, Budak E (1995) Analytical prediction of stability lobes in milling. CIRP Ann 44(1):357–362
Insperger T, Stepan G (2010) Updated semi-discretization method for periodic delay-differential equations with discrete delay. Int J Numer Methods Eng 61(1):117–141
Ding Y, Zhu LM, Zhang XJ, Ding H (2010)Second-order full-discretization method for milling stability prediction. Int J Mach Tools Manuf 50:926–932
Wan M, Ma YC, Zhang WH, Yang Y (2015) Study on the construction mechanism of stability lobes in milling process with multiple modes. Int J Adv Manuf Technol 79:589–603
Qu S, Zhao JB, Wang TR (2016)Three–dimensional stability predication and chatter analysis in milling of thin-walled plate. Int J Adv Manuf Technol 86(5-8):2291–2300
Yang Y, Zhang WH, Ma YC, Wan M (2016) Chatter prediction for the peripheral milling of thin-walled workpiece with curved surfaces. Int J Mach Tools Manuf 109:36–48
Gao J, Song QH, Liu ZQ (2018) Chatter detection and stability region acquisition in thin-walled workpiece milling based on CMWT. Int J Adv Manuf Technol 98:699–713
Budak E, Erturk A, Ozguven HN (2007) Selection of design and operational parameters in spindle-holder-tool assemblies for maximum chatter stability by using a new analytical model. Int J Mach Tools Manuf 47:1401–1409
Wan M, Dang XB, Zhang WH, Yang Y (2018) Optimization and improvement of stable processing condition by attaching additional masses for milling of thin-walled workpiece. Mech Syst Signal Proc 103:196–215
Smis N (2007) Vibration absorbers for chatter suppression: a new analytical tuning methodology. J Sound Vib 301:3–5
Yang YQ, Xu DD, Liu Q (2015) Vibration suppression of thin-walled workpiece machining based on electromagnetic induction. Mater Manuf Process 30(7):829–835
Bolsunovsky S, Vermel V, Gubanov G, Leontiev A (2013) Reduction of flexible workpiece vibrations with dynamic support realized as tuned mass damper. Procedia CIRP 8:230–234
Niu Y, Jiao F, Zhao B, Gao GF (2019) Investigation of cutting force in longitudinal-torsional ultrasonic-assisted milling of Ti-6Al-4V. Materials 12:1955
Peng ZL, Zhang DY, Zhang XY (2020) Chatter stability and precision during high-speed ultrasonic vibration cutting of a thin-walled titanium cylinder. Chin J Aeronaut 33:3535–3549. https://doi.org/10.1016/j.cja.2020.02.011
Tong JL, Wei G, Zhao L, Wang XL, Ma JJ (2019) Surface microstructure of titanium alloy thin-walled parts at ultrasonic vibration-assisted milling. Int J Adv Manuf Technol 101:1007–1021
Chen P, Tong JL, Zhao JS, Zhang ZM, Zhao B (2020) A study of the surface microstructure and tool wear of titanium alloys after ultrasonic longitudinal-torsional milling. J Manuf Process 53:1–11
Wu CJ, Chen SJ, Cheng K, Xiao CW (2020) Investigation of strengthening effect on the machining rigidity in longitudinal torsional ultrasonic milling of thin-plate structures. Proc IMechE Part B: J Eng Manuf 234(3):665–670
Ko JH, Tan SW (2013) Chatter marks reduction in meso-scale milling through ultrasonic vibration assistance parallel to tooling’s axis. Int J Precis Eng Manuf 14(1):17–22
Verma GC, Pandey PM, Dixit US (2018) Modeling of static machining force in axial ultrasonic-vibration assisted milling considering acoustic softening. Int J Mech Sci 136:1–16
Xu WX, Zhang LC (2015) Ultrasonic vibration-assisted machining: principle, design and application. Adv Manuf 3(3):173–192
Ni CB, Zhu LD, Liu CF, Yang ZC (2018) Analytical modeling of tool-workpiece contact rate and experimental study in ultrasonic vibration-assisted milling of Ti-6Al-4V. Int J Mech Sci 142:97–111
Zhang YM, Zhao B, Wang YQ, Chen F (2017) Effect of machining parameters on the stability of separated and unseparated ultrasonic vibration of feed direction assisted milling. J Mech Sci Technol 31(2):851–858
Wan SK, Jin XL, Maroju NK, Hong J (2019) Effect of vibration assistance on chatter stability in milling. Int J Mach Tools Manuf 145:103432
Gao J, Altintas Y (2020) Chatter stability of synchronized elliptical vibration assisted milling. CIRP J Manuf Sci Tec 28:76–86
Tabatabaei SMK, Behbahani S, Mirian SM (2013) Analysis of ultrasonic assisted machining (UAM) on regenerative chatter in turning. J Mater Process Technol 213:418–425
Faassen RPH, van de Wouw N, Oosterling JAJ, Nijmeijer H (2003) Prediction of regenerative chatter by modelling and analysis of high-speed milling. Int J Mach Tools Manuf 43:1437–1446
Acknowledgements
The authors would like to acknowledge Kedong Bi from Southeast University for providing us with the three-coordinate measuring instrument (RA-7525 SEI).
Funding
This work was supported by the National Natural Science Foundation of China (No. 51861145405, No. 52075265); and the Aviation Science Foundation of China (Grant No.20171659001).
Author information
Authors and Affiliations
Contributions
Conceptualization: Kan Zheng, Wenhe Liao; theoretical analysis: Lianjun Sun; experiment and data analysis:Lianjun Sun; manuscript writing: Kan Zheng, Lianjun Sun; constructive discussions: Wenhe Liao, Kan Zheng. All authors have read and agreed to the published version of the manuscript.
Corresponding author
Ethics declarations
Ethics approval
Not applicable
Consent to participate
Not applicable
Consent for publication
Not applicable
Conflict of interest
The authors declare no competing interests.
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Sun, L., Zheng, K. & Liao, W. Chatter suppression and stability analysis of rotary ultrasonic milling titanium alloy thin-walled workpiece. Int J Adv Manuf Technol 118, 2193–2204 (2022). https://doi.org/10.1007/s00170-021-07658-3
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-021-07658-3