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Investigation on cutting forces and tool wear in high-speed milling of Ti-6Al-4V assisted by longitudinal torsional ultrasonic vibrations

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Abstract

The advantage of ultrasonic vibration–assisted milling of titanium alloys has been reported generally under low material removal rate. In this study, high-speed longitudinal-torsion ultrasonic vibration milling (LTUVM) of Ti-6Al-4V was adopted to investigate the cutting forces and tool wear in contrast to conventional milling (CM). In ultrasonic milling, the tool and the workpiece will produce short-term separation, when the cutting speed reaches a critical speed, the tool and the workpiece are no longer separated but always in contact, at which time the cutting speed is called the critical speed. First, the kinematic equation of LTUVM method was constructed, and the critical speed for the cutting separation phenomenon generated by LTUVM was calculated by using the equation of tool tip trajectory. The effects of linear velocity and feed per tooth on the ultrasonic duty cycle were analyzed, and the fitted curves were constructed. Afterwards, the LTUVM system platform was constructed to carry out single factor experiments, exploring the difference of CM and LTUVM processes on the cutting force. The tool wear behaviors of CM and LTUVM were compared under high speed and extensive feeds. The experimental results demonstrated that as the linear velocity increased, during which the ultrasonic cutting separation gradually disappeared, the cutting force improvement effect decreased; however, the tool wear improvement effect was still significant. Such effects of cutting force and tool wear during LTUVM were discussed to reveal its conducive efficiency in high-speed milling of titanium alloy.

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Availability of data and materials

The data presented in this study are available upon request with reasonable causes from the corresponding author.

Funding

This research was funded by the National key research and development program (No.2022YFB4602502), the Guangdong Basic and Applied Basic Research Foundation (2021A1515011991), the Free Exploration Basic Research Project of Local Science and Technology Development Funds Guided by the Central Government (No. 2021Szvup158, No. 2021Szvup159), the Science and Technology Reveal System Project of Hubei Province (2021BEC010), and the Key Research and Development Project of Hubei Province (2022BAA057).

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Authors and Affiliations

  1. School of Mechanical Engineering and Electronic Information, China University of Geosciences, Wuhan, 430074, China

    Guangchao Han & Zejiu Ye

  2. Shenzhen Research Institute, China University of Geosciences, Shenzhen, 518063, China

    Guangchao Han

  3. Division of Advanced Manufacturing, Shenzhen International Graduate School, Tsinghua University, Shenzhen, 518055, China

    Jie Xu, Yuan Ma, Chao Xu, Pingfa Feng & Feng Feng

  4. Shenzhen Tsingding Technology Co., Ltd, Shenzhen, 518108, China

    Yuan Ma, Chao Xu, Xueqi Zhao & Liudong Yu

  5. Department of Mechanical Engineering, Tsinghua University, Beijing, 100084, China

    Pingfa Feng

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  1. Guangchao Han
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Contributions

The authors Guangchao Han, Zejiu Ye, and Feng Feng carried out the research and wrote the original manuscript. Pingfa Feng, Yuan Ma, and Chao Xu assisted with conceptualization of the investigation. Jie Xu, Xueqi Zhao, and Liudong Yu assisted with the data analysis and manuscript editing. All authors have read and agreed to the published version of the manuscript.

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Correspondence to Feng Feng.

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Han, G., Ye, Z., Xu, J. et al. Investigation on cutting forces and tool wear in high-speed milling of Ti-6Al-4V assisted by longitudinal torsional ultrasonic vibrations. Int J Adv Manuf Technol 129, 783–799 (2023). https://doi.org/10.1007/s00170-023-12306-z

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  • DOI: https://doi.org/10.1007/s00170-023-12306-z

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