For a series of unique properties, titanium alloy is widely applied in aviation and aerospace fields. However, the poor machinability makes high-speed machining titanium alloy hardly perform as expected even with advanced tool materials due to the high cutting temperature. Intermittent cutting could be an effective method to decrease the cutting temperature and improve the cutting performance. As typical intermittent cutting methods, traditional ultrasonic vibration cutting (UVC) and elliptical ultrasonic vibration cutting (EUVC) is achieved significant advancements. However, the critical cutting speed confines them to the field of low speed machining. A new type of ultrasonic vibration cutting is proposed, i.e. high-speed ultrasonic vibration cutting (HUVC), in which the vibration is always along with the feed direction. The separation of the tool and workpiece can be realized under some certain conditions although the cutting speed exceeds far away from the critical speed of the traditional UVC and EUVC methods. As a consequence, it realized high speed cutting on a macro level and intermittent cutting in the micro, and improved the machinability of titanium alloy. Firstly, a model of HUVC process was established. Then the feasibility of HUVC method for cutting Ti-6Al-4V is verified experimentally compared with conventional cutting (CC) and traditional ultrasonic vibration cutting (UVC). The results demonstrated that tool life in HUVC are extended by 300% in an optimal situation due to the significantly tool wear reduction. Besides, the cutting efficiency is increased by 90% and cutting force is reduced up to 50% obviously compared with CC method. Furthermore, better surface roughness improvement in a successive cutting process are also achieved.
ZHANG Xiangyu
,
SUI He
,
ZHANG Deyuan
,
JIANG Xinggang
,
WU Ruibiao
. Feasibility Study of High-speed Ultrasonic Vibration Cutting Titanium Alloy[J]. Journal of Mechanical Engineering, 2017
, 53(19)
: 120
-127
.
DOI: 10.3901/JME.2017.19.120
[1] JENOG D K,YOUN H K. High speed machining of aluminum using diamond end mills[J]. International Journal of Machine tool and Manufacture,1997(37):1155-1165.
[2] FALLBOHMER P,RODRIGUEZ C A,OZEL T,et al. High-speed machining of cast iron and alloy steels for die and mold manufacturing[J]. Journal of Materials Processing Technology,2000,98:10.
[3] DEWES R C,ASPINWALL D K. A review of ultra-high speed milling of hardened steels[J]. Journal of Materials Processing Technology,1997,69:1-17.
[4] AXINTE D,DEWES R. High-speed milling of AISI H13 hot-work tool steel using poly crystalline cubic boron nitride ball-nose mills:from experimental investigations and empirical modelling to functional testing of the machined surfaces[J]. Proceedings of the Institution of Mechanical Engineers Part B:Journal of Engineering Manufacture,2010,224(1):15-24.
[5] ZHENG W P,ANSHUL S. High speed ball nose end milling of hardened AISI A2 tool steel with PCBN and coated carbide tools[J]. Journal of Manufacturing Processes,2013,(15):467-473.
[6] KAMEL C A Y,NASSEREDDINE Z,LAKHDAR B,et al. Hard machining of hardened bearing steel using cubic boron nitride tool[J]. Journal of Materials Processing Technology,2009(209):1092-1104.
[7] SAEED Z C,MEHDI T. Surface roughness modelling in hard turning operation of AISI 4140 using CBN cutting tool[J],International Journal of Material Formation,2010,3:233-239.
[8] SCHULZ H,MORIWAKI T. High speed machining[J]. Annl.CIRP,1992,41(2):637-643.
[9] ZHANG S,LI J F,SUN J,et al. Tool wear and cutting forces variation in high-speed end-milling Ti-6Al-4V alloy[J],International Journal of Advanced Manufacturing Technology,2010,46:69-78.
[10] 姜增辉,王琳琳,石莉,等. 硬质合金刀具切削Ti6Al4V的磨损机理及特征[J]. 机械工程学报,2014,50(1):178-184. JIANG Zenghui,WANG Linlin,SHI Li,et al. Study on tool wear mechanism and characteristics of carbide tools in cutting Ti6Al4V[J]. Journal of Mechanical Engineering,2014,50(1):178-184.
[11] SU Y,HE N,LI L,et al. An experimental investigation of effects of cooling/lubrication conditions on tool wear in high-speed end milling of Ti-6Al-4V[J]. Wear,2006,261:760-766.
[12] DINIZ A E,OLIVEIRA A J. Hard turning of interrupted surfaces using CBN tools[J]. Journal of Materials Processing Technology,2008,195:275-281.
[13] LI A H,ZHAO J,LUO H B,et al. Progressive tool failure in high-speed dry milling of Ti-6Al-4V alloy with coated carbide tools[J]. International Journal of Advanced Manufacturing Technology,2012,58:465-478.
[14] N NARUTAKI. High-speed machining of titanium alloy[J]. Chinese Journal of Mechanical Engineering,2002,(15):109-113.
[15] MORIWAKI T,SHAMOTO E. Ultrasonic elliptical vibration cutting[J]. Annals of CIRP,1995,44:31-34.
[16] MA C X,SHAMOTO E,MORIWAKI T,et al. Study of machining accuracy in ultrasonic elliptical vibration cutting[J]. International Journal of Machine Tools and Manufacture,2004,44:1305-1310.
[17] MORIWAKI T,SHAMOTO E. Ultra-precision diamond turning of stainless steel by applying ultrasonic vibration[J]. CIRP Annal. 1991,40:559-562.
[18] XIAO M,WANG Q M,SATOB K,et al. The effect of tool geometry on regenerative instability in ultrasonic vibration cutting[J]. International Journal of Machine Tools and Manufacture,2006,46:492-499.
[19] JIN M,MURAKAWA M. Development of a practical ultrasonic vibration cutting tool system[J]. Journal of Material Processing Technology,2001,113:342-347.
[20] 张翔宇,张德远,隋翯,等. 切深对椭圆超声振动切削机理的影响[J]. 航空学报,2017,38(4):303-311. ZHANG Xiangyu,ZHANG Deyuan,SUI He,et al. Influence of depth of cut on elliptical ultrasonic vibration cutting mechanism[J]. Acta Aeronautical et Astronautical Sinica,2017,38(4):303-311.
[21] 隋翯,张德远,陈华伟,等. 超声振动切削对耦合颤振的影响[J]. 航空学报,2016,37(5):1696-1704. SUI He,ZHANG Deyuan,CHEN Huawei,et al. Influence of ultrasonic vibration cutting on mode-coupling chatter[J]. Acta Aeronautical et Astronautical Sinica,2016,37(5):1696-1704.
[22] 王翀,隋翯,张翔宇,等. 薄壁盘类零件超声振动车削试验研究[J]. 电加工与模具,2016(3):33-35. WANG Chong,SUI He,ZHANG Xiangyu,et al. Experiment study on the ultrasonic vibration turning of thin-wall plate parts[J]. Electromachining and mold,2016(3):33-35.
[23] XU W,ZHANG L. Ultrasonic vibration-assisted machining:Principal,design and application[J]. Advances in Manufacturing,2015,3(3):173-192.
[24] MUHAMMAD R,AHMEDB N,ROY A,et al. Numerical modelling of vibration-assisted turning of Ti-15333[C]//5th CIRP Conference on High Performance Cutting 2012,Procedia CIRP 1(2012) 377-382.
