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Surface feature and material removal in ultrasonic vibration-assisted slot-milling of Ti–6Al–4 V titanium alloy

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Abstract

The continuous optimization of processing technology and evaluation methods is an important way to achieve high processing quality and processing efficiency for difficult-to-process materials. To solve the problem of frequent defects in the slot, the ultrasonic vibration-assisted slot-milling (UVASM) technology was developed for processing titanium alloy. Simultaneously, comparative experiments were carried out between UVASM and conventional slot milling (CSM), in terms of surface features of slot bottom and slot sidewall, cutting force, tool trajectory, chip morphology, and micro-hardness. The results show that uniform vibration micro-texture could significantly improve surface topography of slot bottom in UVASM, while numerous tool feed trajectories and observable machining defects detract from the surface quality in CSM. The UVASM can greatly reduce material spalling and edge breakage, thereby maintaining a smooth and regular edge profile of the slot sidewall. The tool tip trajectories of the two machining methods are highly corresponding to the machining textures of the slot sidewall surface. There is a high-frequency and small-amplitude force fluctuation signal on the axial force waveform in UVASM, which can reduce the instantaneous maximum milling force and milling force in the stable stage by 8.7 and 12.2%, respectively. The UVASM has a better chip breaking effect and surface anti-scratch effect, and the UVASM can obtain higher surface micro-hardness and deeper plastic deformation layer than those CSM. In summary, the multi-dimensional evaluation of slot processing status has been completed, and the processing quality of the slot has been improved.

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Data availability

The datasets used or analyzed during the current study are available from the corresponding author on reasonable request.

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Funding

This study was supported by the Fundamental Research Funds for the Central Universities of Central South University (no. 2021zzts0130).

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Authors and Affiliations

  1. State Key Laboratory of High Performance and Complex Manufacturing, Central South University, Changsha, 410083, China

    Baoqi Chang, Zhaoxi Yi, Xiaobing Cao & Ji-an Duan

  2. College of Mechanical and Electrical Engineering, Central South University, Changsha, 410083, China

    Baoqi Chang, Zhaoxi Yi, Xiaobing Cao & Ji-an Duan

Authors
  1. Baoqi Chang
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  2. Zhaoxi Yi
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  4. Ji-an Duan
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Contributions

All authors contributed to the study’s conception and design. Material preparation and data collection were performed by Baoqi Chang and Zhaoxi Yi. Ji-an Duan and Xiaobing Cao participated in the data analysis and logical analysis of the article. The first draft of the manuscript was written by Baoqi Chang, and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Zhaoxi Yi or Ji-an Duan.

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Chang, B., Yi, Z., Cao, X. et al. Surface feature and material removal in ultrasonic vibration-assisted slot-milling of Ti–6Al–4 V titanium alloy. Int J Adv Manuf Technol 122, 2235–2251 (2022). https://doi.org/10.1007/s00170-022-09970-y

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