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Feasibility study of high feed axial ultrasonic vibration turning of Ti6Al4V

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Abstract

High-feed axial ultrasonic vibration turning (HFUVT) is studied to explore its effects on the machining characteristics of Ti6Al4V alloy. A feed rate that is greater than the ultrasonic vibration amplitude was employed to turn this titanium alloy. The kinematics and tool flank extrusion models were established for the cutting process. Then, systematic simulation and experimental investigations were carried out to compare and analyze the cutting characteristics including the chip geometry, subsurface plastic deformation and cutting force in conventional turning (CT) and HFUVT. The results indicated that the cutting efficiency of HFUVT increased by more than 3.4 times compared with that of CT. The HFUVT produced more severely deformed Sawtooth chips, smaller shear band spacing, higher chip splitting frequency, deeper subsurface plastic deformation layer and lower cutting force. The insightful findings contribute to a comprehensive understanding of the HFUVT process and offer valuable guidance for the improving of cutting efficiency in machining difficult-to-cut materials.

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Acknowledgements

The authors gratefully acknowledge the support of the National Natural Science Foundation of China (NSFC) (Grants No. U22B2086); the National Science and Technology Major Project (Grants 2017-VII-0003-0096); the Defense Industrial Technology Development Program (Grants No. JCKY2020213B006); the National Key Laboratory of Science and Technology on Helicopter Transmission (Grant No. HTL-0-21G04).

Funding

The National Natural Science Foundation of China (NSFC), U22B2086, Jinyuan Tang, the National Science and Technology Major Project, 2017-VII-0003-0096, Jinyuan Tang, the Defense Industrial Technology Development Program, JCKY2020213B006, Wen Shao, the National Key Laboratory of Science and Technology on Helicopter Transmission, HTL-0-21G04, Wen Shao.

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Authors and Affiliations

  1. State Key Laboratory of Precision Manufacturing for Extreme Service Performance, College of Mechanical and Electrical Engineering, Central South University, Changsha, 410083, Hunan, China

    Kaile Li, Wen Shao, Jinyuan Tang, Weiwei Huang & Xin Li

  2. Hunan Engineering Technology Research Center of Digitalization of CNC Machining Process for Precision Parts, Hunan, 410083, China

    Wen Shao

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  1. Kaile Li
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Correspondence to Wen Shao.

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Li, K., Shao, W., Tang, J. et al. Feasibility study of high feed axial ultrasonic vibration turning of Ti6Al4V. Archiv.Civ.Mech.Eng 24, 137 (2024). https://doi.org/10.1007/s43452-024-00951-4

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