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Influence of ultrasonic vibration-assisted cutting on ploughing effect in cutting Ti6Al4V

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Abstract

In this study, the finite element method (FEM) is used to study the ploughing effect of ultrasonic vibration-assisted cutting Ti6Al4V. Due to the existence of the cutting edge radius of the tool, there will be a ploughing area in the cutting of Ti6Al4V. The ploughing area is an area where the stress state is very complex in the cutting process. The ploughing force and temperature of the ploughing area are important factors that affect the machined surface quality and tool wear. The main research of this paper includes the establishment of ploughing force, temperature and dynamic friction coefficient model of the ploughing area, and the correctness of the analysis model is verified by using the finite element method. Then, by changing the cutting conditions, the influence of changing the cutting parameters on the ploughing effect is discussed. The results show that the analysis model can be used to monitor the ploughing force and ploughing area temperature, and ultrasonic vibration-assisted cutting can significantly reduce the ploughing force and ploughing area temperature, reducing tool wear and plastic deformation of the machined surface.

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Abbreviations

α o :

Clearance angle

β :

Friction angle

γ o :

Rake angle

γ o e :

Efficient rake angle

ɛ :

Equivalent plastic strain

\(\bar{\varepsilon }\) :

Average shear strain

λ :

Thermal conductivity

μ :

Coefficient of dynamic friction between tool and workpiece

v 1, v 2 :

Poisson’s ratio of workpiece material and tool material

ρ :

Density of workpiece material

\(\bar{\tau }\) :

Average shear stress

τ max :

Maximum shear stress

τ s :

Shear strength

Φ :

Shear angle

ψ :

Wavelength of ultrasonic wave in elastic medium

A :

Vibration amplitude of tool in x and y direction

A r :

Actual contact area

c :

Specific heat capacity of workpiece material

E * :

Equivalent young's modulus

E c :

Energy consumed per unit shear plane

E d :

Deformation energy

E 1, E 2 :

Young's modulus of workpiece material and tool material

f :

Feed rate

f k :

Tool vibration frequency

F τ :

Shear force on the shear plane

F τn :

Normal force perpendicular to shear plane

F τs :

Resultant force

F c :

Cutting force

F f :

Sliding friction force on tool-chip interface

F n :

Normal force perpendicular to back chip

F p :

Ploughing force

F pc :

Positive pressure perpendicular to cutting edge

F pt :

Tangential force tangent to cutting edge

F t :

Thrust force

F px :

Ploughing force component parallel to cutting speed

F py :

Ploughing force component perpendicular to cutting speed

F rc :

Resultant cutting force

F rt :

Resultant thrust force

H 1, H 2 :

Hardness of workpiece material and tool material

J :

Mechanical equivalent of heat

k :

Heat transfer coefficient of plastic deformation

l :

Coefficient of chip deformation

l f :

Tool-chip contact length

P :

Vertical load

P * :

Amplitude of pressure

P A :

Ploughing area

q f :

Friction heat between tool and chip

q p :

Plastic deformation heat in ploughing area

q p f :

Friction heat between cutting edge and ploughing area material

q s :

Heat flux from shear zone per unit time and unit area

q VB :

Heat caused by flank wear

r ɛ :

Cutting edge radius

s:

Volumetric heat capacity

t :

Depth of cut

T chip, T wp :

Temperature of chip and workpiece

T m :

Melting temperature

T pc−chip, T pc−wp :

Temperature rise of chip and workpiece caused by plastic deformation in ploughing area

T pf−chip, T pf−wp :

Temperature rise of chip and workpiece caused by friction between cutting edge and ploughing area material

T r :

Room temperature

T s−chip, T s−wp :

Temperature of chip and workpiece near the shear plane

T VB−wp :

Temperature rise of processed surface due to the friction of the flank face

u 1 :

Proportion of heat flow from the shear plane to the chip

u 2 :

Heat flow from the tool-chip interface to the chip

u 3 :

Proportion of heat generate by friction of tool flank wear flow into workpiece

v :

Cutting speed

v c :

Chip flow speed

v y :

Velocity of the tool vibration in the y direction

VB:

Tool flank wear width

w :

Width of cut

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Acknowledgements

The authors would like to thank the Science and Technology Planning Project of Shanghai Science and Technology Commission for providing financial support for the paper (20030501100). In particular, the authors would like to thank the editor and reviewers for their constructive suggestions.

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Correspondence to Dazhong Wang.

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Chen, F., Wang, D. & Wu, S. Influence of ultrasonic vibration-assisted cutting on ploughing effect in cutting Ti6Al4V. Archiv.Civ.Mech.Eng 21, 42 (2021). https://doi.org/10.1007/s43452-021-00196-5

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  • DOI: https://doi.org/10.1007/s43452-021-00196-5

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