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.
Similar content being viewed by others
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
References
Amin AKMN, Ismail AF, Khairusshima MKN. Effectiveness of uncoated WC-Co and PCD inserts in end milling of titanium alloy-Ti-6Al-4V.J Mater Process Technol. 2007;192:147–158.
Oezkaya E, Biermann D. Segmented and mathematical model for 3d FEM tapping simulation to predict the relative torque before tool production. Int J Mech Sci. 2017;128:695–708.
Saoubi MR, Outeiro JC, Chandrasekaran H, et al. A review of surface integrity in machining and its impact on functional performance and life of machined products. Int J Sustain Manuf. 2008;1:203–36.
Chen ZZ, Qi H, Zhao B, Zhou Y, Shi L W, Li HN, Ding WF. On the tribology and grinding performance of graphene-modified porous composite-bonded CBN wheel. Ceram Int. 2021; 47(3): 3259–3266.
Wu X, Li L, He N, et al. Investigation on the ploughing force in micro-cutting considering the cutting edge radius. Int J Adv Manuf Technol. 2016;86:1–7.
Wu X, Li L, He N, et al. Influence of the cutting edge radius and the material grain size on the cutting force in micro cutting. Precis Eng. 2016;45:359–64.
Stevenson R. Measurement of parasitic forces in orthogonal cutting. Int J Adv Manuf Technol. 1998;38:113–30.
Chen N, Li L, Wu J, et al. Research on the ploughing force in micro milling of soft-brittle crystals. Int J Mech Sci. 2019;155:315–22.
Chen N, Li HN, Wu JM, et al. Advances in micro milling: from tool fabrication to process outcomes. Int J Mach Tools Manuf. 2021;160:103670.
Chen N, Li ZJ, Wu Y. Investigating the ablation depth and surface roughness of laser-induced nano-ablation of CVD diamond material. Precis Eng. 2019;57:220–8.
Zhou M, Hu L. Development of an innovative device for ultrasonic elliptical vibration cutting. Ultrasonics. 2015;60:76–81.
Brehl DE, Dow TA. Review of vibration-assisted machining. Precis Eng. 2008;32:153–72.
Song YC, Park CH, Moriwaki T. Mirror finishing of Co-Cr-Mo alloy using elliptical vibration cutting. Precis Eng. 2010;34:784–9.
Patil S, Joshi S, Tewari A, et al. Modelling and simulation of effect of ultrasonic vibrations on machining of Ti6Al4V. Ultrasonics. 2014;54:694–705.
Saito H, Jung H, Shamoto E. Elliptical vibration cutting of hardened die steel with coated carbide tools. Precis Eng. 2016;45:44–54.
Davim JP, Maranhao C. A study of plastic strain and plastic strain rate in machining of steel AISI 1045 using FEM analysis. Materi Design. 2009;30:160–5.
Sun ZT, Shuang F, Ma W. Investigations of vibration cutting mechanisms of Ti6Al4V alloy. Int J Mech Sci. 2018;148:510–30.
Yang ZC, Zhu LD, Zhang GX, Ni CB, Lin B. Review of ultrasonic vibration-assisted machining in advanced materials. Int J Mach Tools Manuf. 2020;156:1–34.
Ni CB, Zhu LD. Investigation on machining characteristics of TC4 alloy by simultaneous application of ultrasonic vibration assisted milling (UVAM) and economical-environmental MQL technology. J Mater Process Technol. 2020;278:1–19.
Wang J, Zuo J, Shang Z, et al. Modeling of cutting force prediction in machining high-volume SiCp/Al composites. Appl Math Model. 2019;70:1–17.
Moufki A, Molinari A, Dudzinski D. Modelling of orthogonal cutting with a temperature dependent friction law. J Mech Phys Solids. 1998;46:2103–38.
Bai W, Sun RL. Improved analytical prediction of chip formation in orthogonal cutting of titanium alloy Ti6Al4V. Int J Mech Sci. 2017;133:357–67.
Nath C, Rahman M, Neo KS. Machinability study of tungsten carbide using PCD tools under ultrasonic elliptical vibration cutting. Int J Mach Tools Manuf. 2009;49:1089–95.
Li BK, Li CH, Zhang YB, et al. Heat transfer performance of MQL grinding with different nanofluids for Ni-based alloys using vegetable oil. J Clean Prod. 2017;154:1–11.
Gao T, Li CH, Zhang YB, et al. Dispersing mechanism and tribological performance of vegetable oil-based CNT nanofluids with different surfactants. Tribol Int. 2019;131:51–63.
Heilmann P, Rigney DA. An energy-based model of friction and its application to coated systems. Wear. 1981;72:195–217.
Zhang J, Moslehy FA, Rice SL. A model for friction in quasi-steady-state sliding part I. Derivat Wear. 1991;149:1–12.
Johnson GR, Cook WH. Fracture characteristics of three metals subjected to various strains, strain rates, temperatures and pressures. Eng Fract Mech. 1985;21:31–48.
Ducobu F, Rivière-Lorphèvre E, Filippi E. On the importance of the choice of the parameters of the Johnson–Cook constitutive model and their influence on the results of a Ti6Al4V orthogonal cutting model. Int J Mech Sci. 2017;122:143–55.
Liu K, Melkote SN. Finite element analysis of the influence of tool edge radius on size effect in orthogonal micro-cutting process. Int J Mech Sci. 2007;49:650–60.
Lee WS, Lin CF. High-temperature deformation behaviour of Ti6A14V alloy evaluated by high strain-rate compression tests. J Mater Process Technol. 1998;75:127–36.
Liang X, Liu Z, Wang B, et al. Modeling of plastic deformation induced by thermo-mechanical stresses considering tool flank wear in high-speed machining Ti-6Al-4V. Int J Mech Sci. 2018;140:1–12.
Tan R, et al. Sustainable production of dry-ultra-precision machining of Ti6Al4V alloy using PCD tool under ultrasonic elliptical vibration-assisted cutting. J Clean Prod. 2020;248:119254.
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.
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliation
Rights and permissions
About this article
Cite this article
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
Received:
Revised:
Accepted:
Published:
DOI: https://doi.org/10.1007/s43452-021-00196-5