Abstract

Ti-6Al-4V is widely used in aerospace, medical and defense industries where materials with superior characteristics are needed. However, Ti-6Al-4V is categorized as a difficult-to-cut material, and machining of this alloy is highly challenging. Ultrasonic Assisted Milling (UAM) is a quite recent method to facilitate the machining of difficult-to-cut materials. This method has numerous advantages over the Conventional Milling (CM) method, such as reduced cutting forces and increased surface quality. Besides, Minimum Quantity Lubrication (MQL) is an alternative cooling method to enhance the process efficiency with respect to conventional cooling methods. Cutting force and surface roughness are essential measures to evaluate the cutting performance of a machining process. However, the simultaneous effects of implementing MQL and ultrasonic vibrations in milling operations are not much researched yet. In this study, the combined effects of UAM and MQL on cutting forces and surface roughness during the machining of Ti-6AL-4V are investigated. Results show that the combination of MQL and UAM enhances the cutting forces in rough cutting operations and the surface roughness in both finish and rough cutting operations significantly compared to conventional processes. Consequently, it is concluded that simultaneous implementation of UAM and MQL enhances overall cutting performance in end-milling operation of Ti-6Al-4V.

摘要

Ti-6Al-4V 广泛应用于航空航天、医疗和国防工业，这些行业需要具有优异特性的材料。然而，Ti-6Al-4V 被归类为难切削材料，这种合金的加工极具挑战性。超声波辅助铣削 (UAM) 是一种新近用于加工难切削材料的方法。这种方法与传统铣削 (CM) 方法相比具有许多优点，例如减少切削力和提高表面质量。此外，与传统冷却方法相比，微量润滑 (MQL) 是一种替代冷却方法，可提高工艺效率。切削力和表面粗糙度是评估加工过程切削性能的重要指标。然而，在铣削操作中同时实施 MQL 和超声波振动的效果还没有得到太多研究。在这项研究中，研究了 UAM 和 MQL 对 Ti-6AL-4V 加工过程中切削力和表面粗糙度的综合影响。结果表明，与传统工艺相比，MQL 和 UAM 的组合显着提高了粗切削操作中的切削力以及精切削和粗切削操作中的表面粗糙度。因此，可以得出结论，同时实施 UAM 和 MQL 可提高 Ti-6Al-4V 端铣削操作的整体切削性能。结果表明，与传统工艺相比，MQL 和 UAM 的组合显着提高了粗切削操作中的切削力以及精切削和粗切削操作中的表面粗糙度。因此，可以得出结论，同时实施 UAM 和 MQL 可提高 Ti-6Al-4V 端铣削操作的整体切削性能。结果表明，与传统工艺相比，MQL 和 UAM 的组合显着提高了粗切削操作中的切削力以及精切削和粗切削操作中的表面粗糙度。因此，可以得出结论，同时实施 UAM 和 MQL 可提高 Ti-6Al-4V 端铣削操作的整体切削性能。