Finite element analysis on longitudinal-torsional ultrasonic vibration assisted helical milling of Ti-6Al-4V

In recent years, the use of Ti-6Al-4V alloy in the aviation industry has been increasing. However, due to the difficult machining characteristics of Ti-6Al-4V, hole-drilling in titanium is a major problem plaguing the aviation manufacturing industry. Ultrasonic vibration-assisted machining is a special machining method with excellent advantages such as reduced cutting force and cutting temperature in drilling. To evaluate the distinction, this study attempts to establish a 3D finite element milling simulation model. The differences between Conventional Helical Milling (CHM) and Longitudinal-Torsional Ultrasonic Helical Milling (LTUHM) are compared in the simulation results. The results show that the cutting force and von Mises stress concentration can be effectively reduced in LTUHM, and the chip morphology is fragmentized in CHM while the chip is continuous in LTUHM.