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Analytical model of workpiece temperature in axial ultrasonic vibration-assisted milling in situ TiB2/7050Al MMCs

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Abstract

In recent years, as a new method developed for machining difficult-to-cut materials, ultrasonic vibration-assisted machining technology has been attracting more and more attentions due to its superior properties in reducing cutting temperature. However, analytical models revealing the mechanism and predicting the cutting temperature for ultrasonic vibration-assisted machining are still needed to be developed. In this paper, an analytical model was established to predict the workpiece temperature for ultrasonic vibration-assisted milling of in situ TiB2/Al MMCs. The heat intensity would be directly determined by the cutting force which was significantly influenced by the ultrasonic vibration motion. Meanwhile, the moving heat source theory was applied for calculating dynamic heat flux and partition ratio. Besides, material properties, tool geometry, cutting parameters, and vibration parameters were taken into account for workpiece temperature modeling. Finally, the developed analytical temperature model was validated by milling experiments with and without ultrasonic vibration on in situ TiB2/7050Al metal matrix composites. The relative errors between model prediction results and experiments were smaller than 17%, indicating that the proposed model could provide workpiece temperature prediction reliably and accurately. Furthermore, the established analytical model could be used not only in ultrasonic vibration-assisted milling but also in conventional milling for the metal matrix composites.

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source of 2D orthogonal cutting process. (a) Discretization of the bottom cutting edge, (b) Heat source of orthogonal cutting

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source and image for the workpiece side, (b) Heat source and image for the chip side

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Funding

This work is financially sponsored by the National Natural Science Foundation of China (Grant No. 51775443), National Science and Technology Major Project (Grant No. 2017-VII-0015–0111), and China Postdoctoral Science Foundation (Grant No. 2020M683569).

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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, Kunyang Lin, Junchen Li & 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, Kunyang Lin, Junchen Li & Chenwei Shan

  3. School of Aeronautics and Astronautics, 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. Kunyang Lin
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  6. Junchen Li
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  7. Chenwei Shan
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Contributions

Xiaofen Liu: writing, modeling, methodology, investigation, calculating, and analysis. Wenhu Wang: materials and equipment support. Ruisong Jiang: investigation. Yifeng Xiong: supervision, review and editing, review of experimental setup. Kunyang Lin: checking. Junchen Li: calculation. Chenwei Shan: funding acquisition.

Corresponding author

Correspondence to Yifeng Xiong.

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Liu, X., Wang, W., Jiang, R. et al. Analytical model of workpiece temperature in axial ultrasonic vibration-assisted milling in situ TiB2/7050Al MMCs. Int J Adv Manuf Technol 119, 1659–1672 (2022). https://doi.org/10.1007/s00170-021-08105-z

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  • DOI: https://doi.org/10.1007/s00170-021-08105-z

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