An experimental and FEM study on ultrasonic-assisted turning of titanium alloy

IF 2.7 4区工程技术 Q2 ENGINEERING, MANUFACTURING

Machining Science and Technology Pub Date : 2023-07-04 DOI:10.1080/10910344.2023.2231066

E. Bachir, R. Bejjani

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引用次数: 1

Abstract

Abstract The increase in demand for aerospace parts leads to a need for effective and efficient machining methods to enhance the machinability of titanium alloys. This research investigates the effect of ultrasonic-assisted turning (UAT) on aerospace titanium alloy Ti-6Al-4V by varying cutting parameters. Ultrasonic turning experiments were conducted to investigate the reduction in cutting forces and tool wear at different cutting parameters with wear and surface roughness analysis. Consequently, a finite element model is used to simulate the ultrasonic turning of titanium to have a better understanding of the effect of UAT on stresses and temperature profiles in the process and help explain the results found experimentally. Separation time between the tool and chip was found to be inversely proportional to the cutting speed and the depth of cut with a reduction in cutting forces and surface roughness of up to 42.5% and 61.4%, respectively, for low cutting speed and depth of cut. Tool wear is also shown to decrease in the ultrasonic machining where adhesion-diffusion wear is reduced on the rake face due to separation in the tool-chip interface. The chip temperature was found to increase while the tool temperature is found to decrease with the motion of the tool.

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钛合金超声辅助车削的实验与有限元研究

摘要航空航天零件需求的增加导致需要有效和高效的加工方法来提高钛合金的可加工性。研究了超声辅助车削（UAT）对航空钛合金Ti-6Al-4V的影响。进行了超声波车削实验，通过磨损和表面粗糙度分析，研究了在不同切削参数下切削力和刀具磨损的减少情况。因此，使用有限元模型模拟钛的超声车削，以更好地了解UAT对该过程中应力和温度分布的影响，并有助于解释实验结果。发现刀具和切屑之间的分离时间与切削速度和切削深度成反比，对于低切削速度和低切削深度，切削力和表面粗糙度分别降低42.5%和61.4%。在超声加工中，由于刀具-芯片界面中的分离，前刀面上的粘附扩散磨损减少，刀具磨损也减少。发现切屑温度随着刀具的运动而升高，而刀具温度随着刀具运动而降低。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Machining Science and Technology 工程技术-材料科学：综合

CiteScore

5.70

自引率

3.70%

发文量

审稿时长

6 months

期刊介绍： Machining Science and Technology publishes original scientific and technical papers and review articles on topics related to traditional and nontraditional machining processes performed on all materials—metals and advanced alloys, polymers, ceramics, composites, and biomaterials. Topics covered include: -machining performance of all materials, including lightweight materials- coated and special cutting tools: design and machining performance evaluation- predictive models for machining performance and optimization, including machining dynamics- measurement and analysis of machined surfaces- sustainable machining: dry, near-dry, or Minimum Quantity Lubrication (MQL) and cryogenic machining processes precision and micro/nano machining- design and implementation of in-process sensors for monitoring and control of machining performance- surface integrity in machining processes, including detection and characterization of machining damage- new and advanced abrasive machining processes: design and performance analysis- cutting fluids and special coolants/lubricants- nontraditional and hybrid machining processes, including EDM, ECM, laser and plasma-assisted machining, waterjet and abrasive waterjet machining