Abstract The machinability and tool wear behavior of 7050-T7451 aluminum alloy versus cutting parameters and vibration frequency are compared between conventional cutting (CC) and ultrasonic elliptical vibration cutting (UEVC) processes. A single-factor dry cutting experimental scheme is designed in light of the kinematic property of UEVC. The microstructural evolution in the cutting-layer metal are observed for different cutting parameters and vibration frequencies and the effects of these parameters on the tool wear behavior are investigated for both CC and UEVC. The results indicate that under the same cutting parameters, UEVC requires about three fifths the cutting force required by CC and provides a much higher cutting surface quality than CC. The cutting surface by UEVC shows visible precipitate-free zones (PFZs); the width and intermittent degree of the PFZs are obviously regionalized with vibration frequency, with a critical vibration frequency of 20,000 Hz. For CC, tool wear occurs typically in forms of tipping, spalling wear, or severe adhesive or oxidative wear, whereas for UEVC, tool wear typically mainly consists of impact-induced mechanical wear such as abrasive wear, mild oxidative wear and mild adhesive wear.

中文翻译：

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7050-T7451铝合金超声椭圆振动切削刀具磨损行为分析

摘要 比较了常规切削（CC）和超声椭圆振动切削（UEVC）工艺对7050-T7451铝合金的切削加工性和刀具磨损行为与切削参数和振动频率的关系。针对UEVC的运动学特性，设计了单因素干切削实验方案。观察了不同切削参数和振动频率下切削层金属的微观结构演变，并研究了这些参数对 CC 和 UEVC 刀具磨损行为的影响。结果表明，在相同的切削参数下，UEVC 所需的切削力约为 CC 所需切削力的五分之三，并提供比 CC 高得多的切削表面质量。UEVC 的切割表面显示出可见的无沉淀区 (PFZ)；PFZs的宽度和断续程度随振动频率明显区域化，临界振动频率为20,000 Hz。对于 CC，工具磨损通常以倾翻、剥落磨损或严重粘附或氧化磨损的形式发生，而对于 UEVC，工具磨损通常主要包括冲击引起的机械磨损，例如磨粒磨损、轻度氧化磨损和轻度粘附磨损。