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- Title
Surface integrity investigation into longitudinal-torsional ultrasonic vibration side milling for a TC18 titanium alloy—part I: the effects of cutting speed on cutting force and surface integrity.
- Authors
Xie, Weibo; Zhao, Bo; Liu, Erbo; Chai, Yongbo; Wang, Xikui; Yang, Liquan; Li, Guangxi; Wang, Jian
- Abstract
This paper presents the results of an experimental investigation into the effects of cutting speed on cutting force and surface integrity during which experiments for conventional milling and longitudinal-torsional ultrasonic vibration-assisted milling for machining of a TC18 alloy were performed. Through an analysis of tool-workpiece kinematic characteristics, several advantages of torsional vibration cutting in the non-separated cutting area are illustrated, including variable cutting thickness, variable-front-angle cutting, and chip pulling by the cutter. The cutting force, surface quality, residual stress, and microstructure of the cutting surface were studied in detail during conventional milling and longitudinal-torsional ultrasonic vibration-assisted milling processes at different rotational speeds. The experimental results show that the average radial cutting force and the surface residual compressive stress both decreased with an increase in cutting speed. During the process of torsional vibration milling, the surface roughness increased with an increase in cutting speed before the rotational speed reached the critical speed (1107 rpm) of torsional vibration cutting without separation. After the critical speed was reached, the surface roughness decreased with an increase in cutting speed. Compared with conventional milling, the cutting force and surface roughness of longitudinal-torsional ultrasonic vibration-assisted milling are reduced by 16.05% and 45.65%, respectively. Then, the surface residual compressive stress can be increased by 24.35%. In addition, for both milling processes, the deformation layer thickness increased with an increase in rotational speed, and when the cutting speed is 1400 rpm, the depth of plastic deformation of the vibration milling sample can reach about 7.5 μm. When the rotational speed was greater than 1100 rpm, the grain was significantly elongated and refined along the cutting direction.
- Subjects
TITANIUM alloys; SURFACE forces; CUTTING force; MILLING (Metalwork); TORSIONAL vibration; SPEED; ULTRASONICS
- Publication
International Journal of Advanced Manufacturing Technology, 2022, Vol 120, Issue 3/4, p2701
- ISSN
0268-3768
- Publication type
Article
- DOI
10.1007/s00170-022-08874-1