Surface quality investigation in high-speed dry milling of Ti-6Al-4V by using 2D ultrasonic-vibration-assisted milling platform

doi:10.1007/s40436-023-00473-x

Advances in Manufacturing ›› 2024, Vol. 12 ›› Issue (2): 349-364.doi: 10.1007/s40436-023-00473-x

Surface quality investigation in high-speed dry milling of Ti-6Al-4V by using 2D ultrasonic-vibration-assisted milling platform

Jin Zhang^1,2, Li Ling^1,2,3, Qian-Yue Wang^1,2, Xue-Feng Huang^1,2, Xin-Zhen Kang^1,2, Gui-Bao Tao^1,2, Hua-Jun Cao^1,2

1 College of Mechanical and Vehicle Engineering, Chongqing University, Chongqing 400044, People's Republic of China;
2 State Key Laboratory of Mechanical Transmissions, Chongqing University, Chongqing 400044, People's Republic of China;
3 Aerospace Research Institute of Materials and Processing Technology, Beijing 100076, People's Republic of China

收稿日期:2023-05-29 修回日期:2023-07-20 发布日期:2024-05-16
通讯作者: Hua-Jun Cao,E-mail:hjcao@cqu.edu.cn E-mail:hjcao@cqu.edu.cn
作者简介:Jin Zhang is a Ph.D. candidate at the State Key Laboratory of Mechanical Transmissions, Chongqing University, China. His research interests include ultrasonic vibration-assisted milling device design and manufacture, multi-energy fieldassisted high-speed dry milling green machining technology for difficult-to-machine materials;
Li Ling is a Ph.D. candidate at the State Key Laboratory of Mechanical Transmissions, Chongqing University, China. Her research interests include high-quality and high-efficiency milling technology of difficultto-machine materials;
Qian-Yue Wang is a master degree candidate at the State Key Laboratory of Mechanical Transmissions, Chongqing University, China. Her research interests include green machining technology, exergy efficiency research of machine tool;
Xue-Feng Huang is a master degree candidate at the State Key Laboratory of Mechanical Transmissions, Chongqing University, China. His research interests include ultrasonic toolholder design and manufacture, ultrasonic vibration-assisted milling green machining technology for difficult-to-machine materials;
Xin-Zhen Kang is a master degree candidate at the State Key Laboratory of Mechanical Transmissions, Chongqing University, China. His research interests include smart toolholder design and manufacture, process monitoring of difficult-to-machine materials;
Gui-Bao Tao is an associate professor and master supervisor at the State Key Laboratory of Mechanical Transmissions, Chongqing University, China. His research interests include cryogenic minimum quantity lubrication energy field-assisted green machining technology for difficult-to-machine materials and green manufacturing and equipment;
Hua-Jun Cao is a professor and doctoral supervisor at the State Key Laboratory of Mechanical Transmissions, Chongqing University, China. His research interests include multi-energy field-assisted highspeed dry milling green machining technology for difficult-tomachine materials and green manufacturing and equipment.
基金资助:
Funding was provided by the National Key R&D Program of China(Grant No.2020YFB2010500).

Surface quality investigation in high-speed dry milling of Ti-6Al-4V by using 2D ultrasonic-vibration-assisted milling platform

Jin Zhang^1,2, Li Ling^1,2,3, Qian-Yue Wang^1,2, Xue-Feng Huang^1,2, Xin-Zhen Kang^1,2, Gui-Bao Tao^1,2, Hua-Jun Cao^1,2

1 College of Mechanical and Vehicle Engineering, Chongqing University, Chongqing 400044, People's Republic of China;
2 State Key Laboratory of Mechanical Transmissions, Chongqing University, Chongqing 400044, People's Republic of China;
3 Aerospace Research Institute of Materials and Processing Technology, Beijing 100076, People's Republic of China

Received:2023-05-29 Revised:2023-07-20 Published:2024-05-16
Contact: Hua-Jun Cao,E-mail:hjcao@cqu.edu.cn E-mail:hjcao@cqu.edu.cn
Supported by:
Funding was provided by the National Key R&D Program of China(Grant No.2020YFB2010500).

摘要/Abstract

摘要： Ultrasonic-vibration-assisted milling (UVAM) is an advanced method for the efficient and precise machining of difficult-to-machine materials in modern manufacturing. However, the milling efficiency is limited because the ultrasonic vibration toolholder ER16 collet has a critical cutting speed. Thus, a 2D UVAM platform is built to ensure precision machining efficiency and improve the surface quality without changing the milling toolholder. To evaluate this 2D UVAM platform, ultrasonic-vibration-assisted high-speed dry milling (UVAHSDM) is performed to process a titanium alloy (Ti-6Al-4V) on the platform, and the milling temperature, surface roughness, and residual stresses are selected as the important indicators for performance analysis. The results show that the intermittent cutting mechanism of UVAHSDM combined with the specific spindle speed, feed speed, and vibration amplitude can reduce the milling temperature and improve the texture of the machined surface. Compared with conventional milling, UVAHSDM reduces surface roughness and peak-groove surface profile values and extends the range of residual surface compressive stresses from -413.96 MPa to -600.18 MPa. The excellent processing performance demonstrates the feasibility and validity of applying this 2D UVAM platform for investigating surface quality achieved under UVAHSDM.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-023-00473-x

关键词: 2D ultrasonic-vibration-assisted milling (UVAM) platform, Ultrasonic-vibration-assisted highspeed dry milling (UVAHSDM), Milling temperature, Surface roughness, Residual stress

Abstract: Ultrasonic-vibration-assisted milling (UVAM) is an advanced method for the efficient and precise machining of difficult-to-machine materials in modern manufacturing. However, the milling efficiency is limited because the ultrasonic vibration toolholder ER16 collet has a critical cutting speed. Thus, a 2D UVAM platform is built to ensure precision machining efficiency and improve the surface quality without changing the milling toolholder. To evaluate this 2D UVAM platform, ultrasonic-vibration-assisted high-speed dry milling (UVAHSDM) is performed to process a titanium alloy (Ti-6Al-4V) on the platform, and the milling temperature, surface roughness, and residual stresses are selected as the important indicators for performance analysis. The results show that the intermittent cutting mechanism of UVAHSDM combined with the specific spindle speed, feed speed, and vibration amplitude can reduce the milling temperature and improve the texture of the machined surface. Compared with conventional milling, UVAHSDM reduces surface roughness and peak-groove surface profile values and extends the range of residual surface compressive stresses from -413.96 MPa to -600.18 MPa. The excellent processing performance demonstrates the feasibility and validity of applying this 2D UVAM platform for investigating surface quality achieved under UVAHSDM.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-023-00473-x

Key words: 2D ultrasonic-vibration-assisted milling (UVAM) platform, Ultrasonic-vibration-assisted highspeed dry milling (UVAHSDM), Milling temperature, Surface roughness, Residual stress

Jin Zhang, Li Ling, Qian-Yue Wang, Xue-Feng Huang, Xin-Zhen Kang, Gui-Bao Tao, Hua-Jun Cao. Surface quality investigation in high-speed dry milling of Ti-6Al-4V by using 2D ultrasonic-vibration-assisted milling platform[J]. Advances in Manufacturing, 2024, 12(2): 349-364.

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Surface quality investigation in high-speed dry milling of Ti-6Al-4V by using 2D ultrasonic-vibration-assisted milling platform

Surface quality investigation in high-speed dry milling of Ti-6Al-4V by using 2D ultrasonic-vibration-assisted milling platform

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