Abstract
This research studied the surface homogenization and morphology of a Ti-6Al-4V alloy using the longitudinal-torsional coupled ultrasonic vibration-assisted milling (UVAM) of a ball-end cutter, in which a method of continuous processing between the flat surface and the freeform surface connection was proposed. The cutting experiments compared the UVAM method with the conventional milling (CM) process by setting three parameters: the cutting speed, feeding rate, and depth of cut. The finished surface roughness, the in situ cutting force, and the topography of the surface are characterized in this paper. The surface roughness that resulted from UVAM ball-end milling was much better than the surface roughness of CM at high cutting speeds. In particular, there was a steep decrease of the average roughness rate from 0.668 μm at 4000 rpm to 0.161 μm at 5000 rpm. Moreover, the mean cutting force in ball-end milling using UVAM decreased by 20–40% compared to the CM process. The homogenization of the surface roughness also improved from 59.4 to 15.1% in the UVAM method compared to the CM method when the transverse-longitudinal ratio was taken into consideration. The cutting experiments have not only powerfully demonstrated the validity of the UVAM method but have also shown the beneficial effect that the UVAM process brings.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Milton C, Shaw (2005) Metal cutting principles. Oxford University Press 2, 9–14
Cong W, Pei Z (2015) Handbook of manufacturing engineering and technology, process of ultrasonic machining. Springer-Verlag London 45:1630–1648
Zhou M, Eow YT, Ngoi BKA, Lim EN (2003) Vibration-assisted precision machining of steel with PCD tools. Adv Manuf Proc 18(5):825–834
Nath C, Rahman M (2003) Effect of machining parameters in ultrasonic vibration cutting. Int J Mach Tools Manuf 48(9):965–974
Sun Z, To, S (2018) Effect of machining parameters and tool wear on surface uniformity in micro-milling. Micromachines 9:268–282
Maurotto A, Wickramarachchi CT (2016) Experimental investigations on effects of frequency in ultrasonically-assisted end-milling of AISI 316L: a feasibility study. Ultrasonics 65:113–119
Maurotto A, Muhammad R, Roy A, Silberschmidt VV (2013) Enhanced ultrasonically assisted turning of a β-titanium alloy. Ultrasonics 53(7):1242–1250
Han JG, Lin JQ, Li ZG, Lu MM, Zhang JG (2018) Design and computational optimization of elliptical vibration-assisted cutting system with a novel flexure structure. IEEE T Ind Electron 66(2):1151–1161
Babitsky VI, Kalashnikov AN, Meadows A, Wijesundara AAHP (2003) Ultrasonically assisted turning of aviation materials. J Mater Process Technol 132(1–3):157–167
Geng D, Zhang D, Xu Y, He F, Liu F (2014) Comparison of drill wear mechanism between rotary ultrasonic elliptical machining and conventional drilling of CFRP. J Reinf Plast Compos 33(9):797–809
Zhou M, Wang M, Dong G (2016) Experimental investigation on rotary ultrasonic face grinding of SiCp/Al composites. Adv Manuf Process 31(5):673–678
Zhu X, Lin B, Liu L, Luan Y (2016) Power transfer performance and cutting force effects of contactless energy transfer system for rotary ultrasonic grinding. IEEE T Ind Electron 63(5):2785–2795
Zhang X, Kornel FE, Yu T, Wang W (2016) Cutting forces in micro-end-milling processes. Int J Mach Tools Manuf 107:21–40
Fontaine M, Moufki A, Devillez A, Dudzinski D (2007) Modelling of cutting forces in ball-end milling with tool–surface inclination: part I: predictive force model and experimental validation. J Mater Process Technol 189(1):73–84
Buj-Corral I, Vivancos-Calvet J, Domínguez-Fernández A (2018) Surface topography in ball-end milling processes as a function of feed per tooth and radial depth of cut. Int J Mach Tools Manuf 53(1):151–159
Tangjitsitcharoen S, Thesniyom P, Ratanakuakangwan S (2014) Prediction of surface roughness in ball-end milling process by utilizing dynamic cutting force ratio. J Intell Manuf 28:1–9
Ramos AC, Autenrieth H, Strau T, Deuchert M, Hoffmeister J, Schulze V (2012) Characterization of the transition from ploughing to cutting in micro machining and evaluation of the minimum thickness of cut. J Mater Process Technol 212(3):594–600
Huo, D. H.; Lin, C.; Choong, Z. J.; Ketan;, Pancholi, K.; Degenaar, P. (2015). Surface and subsurface characterisation in micro-milling of monocrystalline silicon. The Int J Adv Manuf Tech, 81(5–8), 1319–1331
Sun ZW, To S, Zhang SJ, Zhang GQ (2018) Theoretical and experimental investigation into non-uniformity of surface generation in micro-milling. Int J Mech Sci
Amini S, Soleimani M, Paktinat H, Lotfi M (2017) Effect of longitudinal–torsional vibration in ultrasonic-assisted drilling. Mater Manuf Process 32(6):616–622
Paktinat H, Amini S (2018) Numerical and experimental studies of longitudinal and longitudinal-torsional vibrations in drilling of AISI 1045. The Int J Adv Manuf Tech 94(5–8):2577–2592
Wang J, Zhang J, Feng P, Guo P, Zhang Q (2018) Feasibility study of longitudinal–torsional-coupled rotary ultrasonic machining of brittle material. J Manuf Sci E-T ASME 140(5):051008
Xiang D, Wu B, Yao Y, Liu Z, Feng H (2019) Ultrasonic longitudinal-torsional vibration-assisted cutting of Nomex® honeycomb-core composites. The Int J Adv Manuf Tech 100(5–8):1521–1530
Wu C, Chen S, Cheng K, Ding H, Xiao C (2018) Innovative design and analysis of a longitudinal-torsional transducer with the shared node plane applied for ultrasonic assisted milling. P I Mech Eng C-J Mec:0954406218797962
Niu Y, Jiao F, Zhao B, Wang D (2017) Multiobjective optimization of processing parameters in longitudinal-torsion ultrasonic assisted milling of Ti-6Al-4V. The Int J Adv Manuf Tech 93(9–12):4345–4356
Suárez A, Veiga F, Lacalle LNLD, Polvorosa R, Lutze S, Wretland A (2016) Effects of ultrasonics-assisted face milling on surface integrity and fatigue life of Ni-alloy 718. J Mater Eng Perform 25(11):5076–5086
Zarchi MMA, Razfar MR, Abdullah A (2013) Influence of ultrasonic vibrations on side milling of AISI 420 stainless steel. Int J Adv Manuf Technol 66(1–4):83–89
Ma CX, Shamoto E, Moriwaki T (2004) Study on the thrust cutting force in ultrasonic elliptical vibration cutting. Mater Sci Forum 471-472:396–400
Tao G, Ma C, Bai L, Shen X, Zhang J (2016) Feed-direction ultrasonic vibration assisted milling surface texture formation. Adv Manuf Proce 32(2):193–198
Yao Z, Kima GY, Faidley LA, Zou Q, Mei D, Chen Z (2012) Acoustic softening and residual hardening in aluminum: modeling and experiments. Int J Plast 39(39):75–87
Hampa PS, Razfar MR, Malaki M, Maleki A (2015) The role of dry aero-acoustical lubrication and material softening in ultrasonically assisted milling of difficult-to-cut AISI 304 steels. T Indian I Metals 68(1):43–49
Feng P, Wang J, Zhang J, Zhijun WU (2017) Research status and future prospects of rotary ultrasonic machining of hard and brittle materials. Chin J Mech Eng-En 53(19):3–21
Wang Y, Gong H, Fang FZ, Ni H (2016) Kinematic view of the cutting mechanism of rotary ultrasonic machining by using spiral cutting tools [J]. The Int J Adv Manuf Tech 83(1–4):461–474
Funding
This work was supported by China-EU H2020 International Science and Technology Cooperation Programme (FabSurfWAR Nos. 2016YFE0112100 and 644971) and Jilin Province Science and Technology Development Program Supported Project (20180201057GX).
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Electronic supplementary material
ESM 1
(DOCX 427 kb)
Rights and permissions
About this article
Cite this article
Ren, W., Xu, J., Lin, J. et al. Research on homogenization and surface morphology of Ti-6Al-4V alloy by longitudinal-torsional coupled ultrasonic vibration ball-end milling. Int J Adv Manuf Technol 104, 301–313 (2019). https://doi.org/10.1007/s00170-019-03668-4
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-019-03668-4