The interaction mechanism between the tool flank wear and the cutting force, in milling Ti-6Al-4V, is of significance for its further development. However, the relationship between the tool flank wear and the cutting force should be further investigated under ultrasonic-assisted milling. In this study, the longitudinal-torsional ultrasonic-assisted milling (LTUAM) Ti-6Al-4V in dry cutting was evaluated by comparing with conventional milling (CM). With the consideration of the ultrasonic vibration on the chip flow angle, a novel cutting force model in terms of the tool flank wear was developed by discretizing the side edge to apply the oblique model. Wherein the stress evolution both on the shear plane and the flank plane was analyzed, as well as the swinging range of chip flow angle resulted from ultrasonic vibration. In addition, the coefficients of the cutting force were calibrated through the mechanical method. The model could predict the cutting force evolution with different flank wear bandwidth (VB), and optimize the machining parameters. The experimental results indicated the errors between the model and the test were 19.1 % and 12.9 % in the feed (x) and the normal (y) direction of the tool coordinate system (o-xyz), respectively. Through time-frequency transformation, the behavior of the cutting force both in CM and LTUAM was further explained. Besides, the growing amplitude was beneficial to restrain the flank wear apart from the overgrowing amplitude, while the growing helix angles resulted in the serious tool flank wear in LTUAM. For the machined surface texture, the cutter scratches parallel to the feed direction dominated the machined surface in CM while the LTUAM surface featured by the order wave textures.

铣削Ti-6Al-4V时，刀具侧面磨损与切削力之间的相互作用机理对其进一步发展具有重要意义。但是，在超声辅助铣削下，应进一步研究刀具侧面磨损与切削力之间的关系。在这项研究中，通过与传统铣削（CM）进行比较，评估了干切削中的纵向扭转超声辅助铣削（LTUAM）Ti-6Al-4V。考虑到切屑流角上的超声振动，通过离散化侧边以应用倾斜模型，开发了一种针对刀具侧面磨损的新型切削力模型。分析了在剪切面和侧面的应力变化，以及超声振动引起的切屑流角的摆动范围。此外，切削力系数通过机械方法进行校准。该模型可以预测不同侧面磨损带宽下的切削力演变（VB），并优化加工参数。实验结果表明，模型和测试之间的误差在刀具坐标系的进给（x）和法向（y）方向上分别为19.1％和12.9％（o - xyz）， 分别。通过时频变换，进一步解释了切削力在CM和LTUAM中的行为。此外，振幅的增大除了抑制振幅过大外，还有助于抑制齿面磨损，而螺旋角的增大导致LTUAM中严重的刀具齿面磨损。对于加工后的表面纹理，刀具在平行于进给方向的划痕占优势，在CM中，加工后的表面占主导地位，而LTUAM表面则由有序波纹理表征。