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Theoretical and experimental investigation into the machining performance in axial ultrasonic vibration-assisted cutting of Ti6Al4V

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Abstract

Axial ultrasonic vibration-assisted cutting (AUVC) has been proved to have better machining performance compared with conventional cutting methods; however, the effect of numerous and complex influencing factors on machining performance has not been clearly revealed, and a recommended combination of cutting conditions has not been proposed yet, especially for difficult-to-machine material such as Ti6Al4V alloy. This paper focuses on the experimental and theoretical investigation into Ti6Al4V machining performance with AUVC method. First, a retrospective of the separation characteristics of AUVC is provided, and the variable parameter cutting characteristics are demonstrated. The influencing factors on machining performance are classified into four categories: machining parameters, vibration parameters, tool choice, and cooling conditions. The relationship between these factors in terms of their effect on machining performance is established theoretically. Then, it describes experiments to determine the influence of these factors on cutting force, tool life, and surface roughness. For absolute influence, the orders for cutting force, tool life, and surface roughness are respectively cutting depth > amplitude > feed rate > rotation speed, rotation speed > feed rate > amplitude > cutting depth, and feed rate > amplitude > cutting depth > rotation speed. However, for relative influence, the order is unified as amplitude > feed rate > rotation speed > cutting depth. Finally, it suggests a smaller feed rate, larger amplitude, moderate rotation speed, and smaller cutting depth in addition to a WC tool coated with TiAlN and used under HPC cooling condition for optimal performance of AUVC. This recommendation is based on the theoretical analysis and experimental results of cutting force, surface roughness, and tool life.

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Availability of data and materials

All data generated or analyzed during this study are included in this published article, and further request can be contacted with the corresponding author.

Funding

This work was supported by the Research Start-up Fund of Civil Aviation University of China (grant no. 2020KYQD81).

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Authors and Affiliations

  1. College of Aeronautical Engineering, Civil Aviation University of China, Tianjin, 300300, China

    He Sui & Lifeng Zhang

  2. Information Security Evaluation Center of Civil Aviation, Civil Aviation University of China, Tianjin, 300300, China

    Shuang Wang & Zhaojun Gu

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  1. He Sui
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  2. Lifeng Zhang
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  3. Shuang Wang
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Contributions

Author He Sui carried out theoretical and experimental study of this paper and was a major contributor in writing the manuscript. Author Lifeng Zhang contributed to the conception of the study and helped perform the theoretical analysis part with constructive discussions. Author Shuang Wang performed the data analyses and wrote the manuscript. Author Zhaojun Gu contributed significantly to analysis and manuscript preparation.

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Correspondence to He Sui.

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Sui, H., Zhang, L., Wang, S. et al. Theoretical and experimental investigation into the machining performance in axial ultrasonic vibration-assisted cutting of Ti6Al4V. Int J Adv Manuf Technol 116, 449–472 (2021). https://doi.org/10.1007/s00170-021-07447-y

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