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Cutting performance and surface quality of Ti-6Al-4V by longitudinal ultrasonic vibration-assisted high-speed dry milling with coated carbide tools

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Abstract

Longitudinal ultrasonic vibration-assisted high-speed dry milling (LUVAHSDM) is adopted to improve the cutting performance and surface quality of Ti-6Al-4V (TC4). Multifaceted comparisons are presented in terms of milling force, milling temperature, tool wear, 3D surface roughness, and residual stress, utilizing AlCrN, AlCrSiN, AlTiN, and AlTiSiN-coated tools. The results show that the maximum milling forces in the feed and longitudinal directions both decreased at first and then increased with the increasing of Al element contents, during which the single edge and average flank wear increased. Therefore, the surface roughness of TC4 becomes more uniform using AlTiN-coated tools, and the residual stress is significantly reduced to 98.57 MPa. Combining the results of milling force, milling temperature, tool wear, 3D surface roughness and residual stress data, it is found that AITiN-coated tools achieve excellent cutting performance and surface quality. The excellent machining performance of coated carbide tools demonstrates the feasibility and effectiveness of applying LUVAHSDM methods.

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All authors confirm that the data supporting the findings of this study are available within the article.

Abbreviations

CM:

Conventional milling

HSM:

High-speed machining

HSDM:

High-speed dry milling

UVAM:

Ultrasonic vibration-assisted milling

LUVAM:

Longitudinal ultrasonic vibration-assisted milling

LUVAHSDM:

Longitudinal ultrasonic vibration-assisted high-speed dry milling

Fx max :

Maximal cutting force component in the radial direction (N)

Fy max :

Maximal cutting force component in the feed direction (N)

Fz max :

Maximal cutting force component in the longitudinal direction (N)

F max :

The maximum milling resultant forces (N)

Fx ave :

Average cutting force component in the radial direction (N)

Fy ave :

Average cutting force component in the feed direction (N)

Fz ave :

Average cutting force component in the longitudinal direction (N)

F ave :

The average milling resultant forces (N)

T max :

Maximum cutting temperature (°C)

T ave :

Average of maximum cutting temperature (°C)

FW :

Single edge flank wear (μm)

Sq :

Root mean square roughness evaluated over the complete 3D surface (μm)

Sa :

Average roughness evaluated over the complete 3D surface (μm)

RS :

Residual stress of the machined surface (MPa)

v c :

Cutting speed (m/min)

f z :

Feed per tooth (mm/z)

α p :

Axial cutting depth (mm)

α e :

Radial cut width (mm)

f :

Vibration frequency (kHz)

A :

Vibration amplitude (μm)

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Funding

This work was supported by National Key R&D Program of China (2020YFB2010500).

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Authors and Affiliations

  1. College of Mechanical and Vehicle Engineering, Chongqing University, Chongqing, 400044, China

    ** Zhang, Li Ling, Daixin Luo, Chenjie Deng, Xuefeng Huang, Guibao Tao & Huajun Cao

  2. State Key Laboratory of Mechanical Transmissions, Chongqing University, Chongqing, 400044, China

    ** Zhang, Li Ling, Daixin Luo, Chenjie Deng, Xuefeng Huang, Guibao Tao & Huajun Cao

  3. Aerospace Research Institute of Materials & Processing Technology, Bei**g, 100076, China

    Li Ling

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Contributions

** Zhang: Conceptualization; investigation; methodology; validation; roles/writing—original draft

Li Ling: Software; data curation

Daixin Luo: Visualization

Chenjie Deng: Data curation

Xuefeng Huang: Review and editing

Guibao Tao: Writing—review and editing; project administration; funding acquisition; resources

Huajun Cao: Supervision; writing—review and editing; project administration; funding acquisition; resources

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Correspondence to Guibao Tao or Huajun Cao.

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Appendices

Appendix 1

Table 5 Flank wear of LUVAHSDM TC4 with different coated tools
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Appendix 2

Table 6 Residual stress of LUVAHSDM TC4 with different coated tools
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Zhang, J., Ling, L., Luo, D. et al. Cutting performance and surface quality of Ti-6Al-4V by longitudinal ultrasonic vibration-assisted high-speed dry milling with coated carbide tools. Int J Adv Manuf Technol 126, 5583–5596 (2023). https://doi.org/10.1007/s00170-023-11510-1

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