Machining temperature is a key factor in ultrasonic vibration-assisted milling as it can significantly influence tool wear rate and residual thermal stresses. In current study, a physics-based analytical predictive model on machining temperature in ultrasonic vibration-assisted milling is proposed, without resorting to iterative numerical simulations. As the tool periodically loses contact with the workpiece under vibration, three types of tool-workpiece separation criteria are first examined based on the tool trajectory under ultrasonic vibration. Type I criterion examines whether the relative velocity between tool and workpiece in cutting direction is opposite to the tool rotation direction. Type II criterion examines whether the instantaneous vibration displacement in radial direction is larger than instantaneous uncut chip thickness. Type III criterion examines whether there is overlap between current and previous tool paths due to vibration. If no contact, the instantaneous temperature rise is zero. Otherwise, the temperature rise is predicted under shearing heat source in shear zone and secondary rubbing heat source along machined surface. A mirror heat source method is applied to predict temperature rise, considering oblique band heat sources moving in a semi-infinite medium. The proposed predictive temperature model in ultrasonic vibration-assisted milling is validated through comparison to experimental measurements on Al 6063 alloy. The proposed predictive model is able to match the measured temperature with high accuracy of 1.85% average error and 5.22% largest error among all cases. Sensitivity analysis is also conducted to study the influences of cutting and vibration parameters on temperature. The proposed model is valuable in terms of providing an accurate and reliable reference for the prediction of temperature in ultrasonic vibration-assisted milling.

中文翻译：

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超声振动辅助铣削的温度预测

加工温度是超声振动辅助铣削的关键因素，因为它可以显着影响刀具磨损率和残余热应力。在当前的研究中，提出了一种基于物理的超声波振动辅助铣削加工温度分析预测模型，而不是求助于迭代数值模拟。由于刀具在振动下周期性地失去与工件的接触，因此首先根据超声波振动下的刀具轨迹检查三种刀具-工件分离标准。I 类判据检查刀具与工件在切削方向上的相对速度是否与刀具旋转方向相反。II 类判据检查径向瞬时振动位移是否大于瞬时未切削切屑厚度。类型 III 标准检查当前和以前的刀具路径之间是否由于振动而重叠。如果没有接触，瞬时温升为零。否则，在剪切区的剪切热源和沿加工表面的二次摩擦热源下预测温升。考虑到在半无限介质中运动的斜带热源，应用镜面热源方法来预测温升。通过与 Al 6063 合金的实验测量值进行比较，验证了所提出的超声振动辅助铣削中的预测温度模型。所提出的预测模型能够以1.85%的平均误差和5.22%的最大误差在所有情况下高精度地匹配测量温度。还进行了敏感性分析以研究切削和振动参数对温度的影响。所提出的模型在为超声振动辅助铣削中的温度预测提供准确可靠的参考方面具有重要价值。