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Groove bottom material removal mechanism and machinability evaluation for longitudinal ultrasonic vibration–assisted milling of Al-50wt% Si alloy

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Abstract

The anisotropy, inhomogeneity, high brittleness, and hardness of Al-50wt% Si alloy challenge its machinability in conventional processing. To solve the problem of serious machined surface defects on the groove bottom, the longitudinal ultrasonic vibration–assisted milling (LUVAM) technique was developed for Al-50wt% Si alloy groove machining. Based on the characteristics of tool-workpiece separation and frictional reversal, the variation of cutting force and cutting temperature with amplitude was studied. The influence of amplitude on the material removal mechanism and surface formation characteristics of Al-50wt% Si alloy groove bottom under different material removal rates (precision and non-precision milling (PM and NPM)) were the focus of this paper. The results show that the probability of Si particle breakage and spalling in PM decreases with the increase of amplitude, and the particles are sheared instead. The ultrasonic dressing effect reduces the anisotropy of Al-50wt% Si alloy. However, in NPM, the ultrasonic dressing effect weakens and the dynamic impact effect increases when the amplitude exceeds the critical value 2.5 μm. Additionally, the groove bottom surface features are related to the down milling (DM) and up milling (UM) methods. UM is the better method for PM of Al-50wt% Si alloy, and DM is the better method for NPM of Al-50wt% Si alloy. This work suggests that under different material removal rates, the machined groove quality of Al-50wt% Si alloy can be improved by selection of optimized amplitude in LUVAM.

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Funding

This work is financially supported by the National Natural Science Foundation of China (nos. 52075168, 52275424), the Project of Department of Education of Hunan Province (no. 22A0331), and the Hunan Postgraduate Research Innovation Project Fund (no. CX20221051).

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Authors and Affiliations

  1. School of Mechanical Engineering, Hunan University of Science and Technology, Xiangtan, 411201, People’s Republic of China

    Lu Jing, Qiulin Niu, Wenhui Yue, Jie Rong, Hang Gao & Siwen Tang

  2. Hunan Provincial Key Laboratory of High Efficiency and Precision Machining of Difficult-to-Cut Material, Hunan University of Science and Technology, Xiangtan, 411201, People’s Republic of China

    Lu Jing, Qiulin Niu, Wenhui Yue, Jie Rong & Hang Gao

  3. Hunan Provincial Key Laboratory of Health Maintenance for Mechanical Equipment, Hunan University of Science and Technology, Xiangtan, 411201, People’s Republic of China

    Siwen Tang

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  1. Lu Jing
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Contributions

Lu Jing: conceptualization, methodology, investigation, data collection and analysis, writing — original draft. Qiulin Niu: conceptualization, methodology, funding acquisition, writing — review and editing. Wenhui Yue: conceptualization, writing — review and editing, supervision. Jie Rong: investigation, methodology. Hang Gao: methodology. Siwen Tang: supervision, funding acquisition.

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Correspondence to Qiulin Niu or Wenhui Yue.

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We would like to submit the manuscript entitled “Groove bottom material removal mechanism and machinability evaluation for longitudinal ultrasonic vibration–assisted milling of Al-50wt% Si alloy” by Lu Jing, Qiulin Niu, Wenhui Yue, Jie Rong, Hang Gao, and Siwen Tang, and we wish to be considered for publication in the International Journal of Advanced Manufacturing Technology.

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Jing, L., Niu, Q., Yue, W. et al. Groove bottom material removal mechanism and machinability evaluation for longitudinal ultrasonic vibration–assisted milling of Al-50wt% Si alloy. Int J Adv Manuf Technol 127, 365–380 (2023). https://doi.org/10.1007/s00170-023-11548-1

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