Tool wear mechanisms in axial ultrasonic vibration assisted milling in-situ TiB2/7050Al metal matrix composites

doi:10.1007/s40436-020-00294-2

Advances in Manufacturing ›› 2020, Vol. 8 ›› Issue (2): 252-264.doi: 10.1007/s40436-020-00294-2

• ARTICLES • 上一篇

Tool wear mechanisms in axial ultrasonic vibration assisted milling in-situ TiB₂/7050Al metal matrix composites

Xiao-Fen Liu¹, Wen-Hu Wang¹, Rui-Song Jiang², Yi-Feng Xiong¹, Kun-Yang Lin¹

1 School of Mechanical Engineering, Northwestern Polytechnical University, Xi'an 710072, People's Republic of China;
2 School of Aeronautics and Astronautics, Sichuan University, Chengdu 610065, People's Republic of China

收稿日期:2019-07-22 修回日期:2019-10-02 出版日期:2020-06-25 发布日期:2020-06-08
通讯作者: Xiao-Fen Liu E-mail:xiaofl1987@mail.nwpu.edu.cn
基金资助:
This work is sponsored by the National Natural Science Foundation of China (Grant No. 51775443), the Innovation Foundation for Doctor Dissertation of Northwestern Polytechnical University (Grant No. CX201829), and the National Science and Technology Major Project (Grant No. 2017-VII-0015-0111).

Tool wear mechanisms in axial ultrasonic vibration assisted milling in-situ TiB₂/7050Al metal matrix composites

Xiao-Fen Liu¹, Wen-Hu Wang¹, Rui-Song Jiang², Yi-Feng Xiong¹, Kun-Yang Lin¹

1 School of Mechanical Engineering, Northwestern Polytechnical University, Xi'an 710072, People's Republic of China;
2 School of Aeronautics and Astronautics, Sichuan University, Chengdu 610065, People's Republic of China

Received:2019-07-22 Revised:2019-10-02 Online:2020-06-25 Published:2020-06-08
Contact: Xiao-Fen Liu E-mail:xiaofl1987@mail.nwpu.edu.cn
Supported by:
This work is sponsored by the National Natural Science Foundation of China (Grant No. 51775443), the Innovation Foundation for Doctor Dissertation of Northwestern Polytechnical University (Grant No. CX201829), and the National Science and Technology Major Project (Grant No. 2017-VII-0015-0111).

摘要/Abstract

摘要： The in-situ TiB₂ particle reinforced aluminum matrix composites are materials that are difficult to machine, owing to hard ceramic particles in the matrix. In the milling process, the polycrystalline diamond (PCD) tools are used for machining these materials instead of carbide cutting tools, which significantly increase the machining cost. In this study, ultrasonic vibration method was applied for milling in-situ TiB₂/7050Al metal matrix composites using a TiAlN coated carbide end milling tool. To completely understand the tool wear mechanism in ultrasonic-vibration assisted milling (UAM), the relative motion of the cutting tool and interaction of workpiecetool-chip contact interface was analyzed in detail. Additionally, a comparative experimental study with and without ultrasonic vibration was carried out to investigate the influences of ultrasonic vibration and cutting parameters on the cutting force, tool life and tool wear mechanism. The results show that the motion of the cutting tool relative to the chip changes periodically in the helical direction and the separation of tool and chip occurs in the transverse direction in one vibration period, in ultrasonic vibration assisted cutting. Large instantaneous acceleration can be obtained in axial ultrasonic vibration milling. The cutting force in axial direction is significantly reduced by 42%-57%, 40%-57% and 44%-54%, at different cutting speeds, feed rates and cutting depths, respectively, compared with that in conventional milling. Additionally, the tool life is prolonged approximately 2-5 times when the ultrasonic vibration method is applied. The tool wear pattern microcracks are only found in UAM. These might be of great importance for future research in order to understand the cutting mechanisms in UAM of in-situ TiB₂/7050Al metal matrix composites.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-020-00294-2

关键词: Aluminum matrix composites, Ultrasonic vibration, Milling, Cutting force, Tool wear

Abstract: The in-situ TiB₂ particle reinforced aluminum matrix composites are materials that are difficult to machine, owing to hard ceramic particles in the matrix. In the milling process, the polycrystalline diamond (PCD) tools are used for machining these materials instead of carbide cutting tools, which significantly increase the machining cost. In this study, ultrasonic vibration method was applied for milling in-situ TiB₂/7050Al metal matrix composites using a TiAlN coated carbide end milling tool. To completely understand the tool wear mechanism in ultrasonic-vibration assisted milling (UAM), the relative motion of the cutting tool and interaction of workpiecetool-chip contact interface was analyzed in detail. Additionally, a comparative experimental study with and without ultrasonic vibration was carried out to investigate the influences of ultrasonic vibration and cutting parameters on the cutting force, tool life and tool wear mechanism. The results show that the motion of the cutting tool relative to the chip changes periodically in the helical direction and the separation of tool and chip occurs in the transverse direction in one vibration period, in ultrasonic vibration assisted cutting. Large instantaneous acceleration can be obtained in axial ultrasonic vibration milling. The cutting force in axial direction is significantly reduced by 42%-57%, 40%-57% and 44%-54%, at different cutting speeds, feed rates and cutting depths, respectively, compared with that in conventional milling. Additionally, the tool life is prolonged approximately 2-5 times when the ultrasonic vibration method is applied. The tool wear pattern microcracks are only found in UAM. These might be of great importance for future research in order to understand the cutting mechanisms in UAM of in-situ TiB₂/7050Al metal matrix composites.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-020-00294-2

Key words: Aluminum matrix composites, Ultrasonic vibration, Milling, Cutting force, Tool wear

Xiao-Fen Liu, Wen-Hu Wang, Rui-Song Jiang, Yi-Feng Xiong, Kun-Yang Lin. Tool wear mechanisms in axial ultrasonic vibration assisted milling in-situ TiB₂/7050Al metal matrix composites[J]. Advances in Manufacturing, 2020, 8(2): 252-264.

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Tool wear mechanisms in axial ultrasonic vibration assisted milling in-situ TiB₂/7050Al metal matrix composites

Tool wear mechanisms in axial ultrasonic vibration assisted milling in-situ TiB₂/7050Al metal matrix composites

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