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Design and surface analysis in large-amplitude longitudinal ultrasonic vibration-assisted milling of TC4 titanium alloy under dry conditions

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Abstract

Exploring advanced green processing technology is the way to achieve efficient precision manufacturing of difficult-to-machine materials and carbon-neutral development. Thus, the design and manufacture of a large-amplitude longitudinal ultrasonic vibration-assisted milling (LALUVAM) toolholder is conducted in this work. For validation of the developed toolholder a TC4 titanium alloy milling experiment is carried out. Multifaceted analysis are presented in terms of milling force, surface roughness, and residual stress. The results indicate that the LALUVAM toolholder exhibits excellent performance in milling TC4 materials. What’s more, the disordered tool feed trajectory is eliminated when using the LALUVAM toolholder in milling TC4. Moreover, resultant forces F is reduced 36.61%. The minimum surface roughness and a smaller range of compressive residual stress can be obtained under LALUVAM condition. Meanwhile, a scaled texture can be generated on the surface of TC4 by using harmonic movement of end mill. In the future, LALUVAM toolholder will be able to meet the 10 μm to 20 μm ultrasonic machining and provide better results in terms of reduced milling forces and surface roughness.

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Data availability

All authors confirm that the data supporting the findings of this study are available within the article.

Abbreviations

LALUVAM:

Large-amplitude longitudinal ultrasonic vibration-assisted milling

CDM :

Conventional dry milling

LAM :

Laser-assisted milling

UVAM :

Ultrasonic vibration-assisted milling

CMQLAM:

Cryogenic minimum quantity lubrication-assisted milling

CM:

Conventional milling

LUVAM :

Longitudinal ultrasonic vibration-assisted milling

A :

Ultrasonic amplitude

n :

Spindle speed

FEM:

Finite element method

TOL:

Tool overhang length

TSAUCS:

Two-stage amplified ultrasound conversion system

UGS:

Ultrasonic generator system

TSS:

Toolholder shell system

ETS:

Electrical transmission system

f :

Frequency

PZT:

Piezoelectric

UCS:

Ultrasound conversion system

AC:

Alternating current

PWM:

Pulse width modulation

DC:

Direct current

F :

Resultant forces

f z :

Feed per tooth

Sq :

Root mean square surface roughness

Sa :

Average surface roughness

z :

The number of milling flute

a p :

Axial cutting depth

a e :

Radial cut width

CRS:

Compressive residual stress

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Funding

This work was supported by National Key R&D Program of China (2020YFB2010500) and Graduate Research and Innovation Foundation of Chongqing, China (Grant No. CYB23017).

Author information

Authors and Affiliations

  1. College of Mechanical and Vehicle Engineering, Chongqing University, Chongqing, 400044, China

    Jin Zhang, Xuefeng Huang, Qianyue Wang, Guibao Tao & Huajun Cao

  2. State Key Laboratory of Mechanical Transmissions, Chongqing University, Chongqing, 400044, China

    Jin Zhang, Xuefeng Huang, Qianyue Wang, Guibao Tao & Huajun Cao

  3. Division for Digital and Flexible dAssembly, AVIC Manufacturing Technology Institute, Beijing, 100024, China

    Yu Fu

Authors
  1. Jin Zhang
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  2. Xuefeng Huang
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  3. Yu Fu
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Contributions

Jin Zhang: Conceptualization; Investigation; Methodology; Validation; Roles/Writing-original draft. Xuefeng Huang: Software. Yu Fu: Data curation. Qianyue Wang: Review & editing. Guibao Tao: Project administration; Funding acquisition. Huajun Cao: Supervision; Writing-review & editing; Project administration; Funding acquisition; Resources.

Corresponding author

Correspondence to Huajun Cao.

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Appendix A

Appendix A

The effect of milling parameters on the measured milling force

No.

n (r/min)

fz(mm/z)

Force Fx (N)

Force Fy (N)

Force Fz (N)

CM

LALUVAM

CM

LALUVAM

CM

LALUVAM

1

1200

0.02

94.09

74.46

96.85

82.81

37.17

33.83

2

1200

0.03

98.34

90.50

99.94

94.78

40.14

36.43

3

1200

0.04

111.10

97.23

102.20

96.74

41.83

38.77

4

1200

0.05

123.10

114.30

113.20

107.97

42.57

39.65

5

1600

0.02

97.73

93.14

104.90

99.01

39.18

38.20

6

1600

0.03

105.30

93.08

107.80

98.52

43.02

39.05

7

1600

0.04

120.70

105.40

116.20

101.70

43.47

39.27

8

1600

0.05

113.00

107.70

114.80

98.90

38.88

37.39

9

2000

0.02

76.37

47.47

66.00

42.91

21.59

13.67

10

2000

0.03

69.69

60.53

60.86

54.06

20.58

15.55

11

2000

0.04

79.15

73.08

62.34

56.88

22.68

17.94

12

2000

0.05

84.17

83.13

62.00

60.63

20.29

17.52

13

2400

0.02

81.75

73.48

71.34

65.75

23.38

18.93

14

2400

0.03

95.92

81.05

78.28

72.17

26.49

19.27

15

2400

0.04

95.48

89.76

81.29

77.4

28.08

25.38

16

2400

0.05

105.8

98.02

83.17

78.04

27.77

26.65

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Zhang, J., Huang, X., Fu, Y. et al. Design and surface analysis in large-amplitude longitudinal ultrasonic vibration-assisted milling of TC4 titanium alloy under dry conditions. Int J Adv Manuf Technol (2024). https://doi.org/10.1007/s00170-024-13765-8

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