Experimental study on surface residual stress of titanium alloy curved thin-walled parts by ultrasonic longitudinal-torsional composite milling
Tóm tắt
The production of thin-walled titanium alloy curved surfaces is of great significance to aerospace manufacturing industry. The magnitude and distribution of residual stress are one of the important factors affecting the surface integrity of the workpiece. In order to obtain larger surface residual compressive stress, improve the surface integrity of the workpiece, and realize the fatigue-resistant manufacturing, the ultrasonic longitudinal-torsional composite milling method was proposed. Orthogonal and single-factor experiments were carried out on titanium alloy curved thin-walled parts, and the differences of cutting force, cutting temperature, and residual stress between conventional milling and ultrasonic longitudinal-torsional composite milling were compared and analyzed, and the influence of different process parameters on the surface residual stress of titanium alloy thin-walled parts was explored. Compared with conventional milling, the surface residual stress values of ultrasonic longitudinal-torsional composite milling workpiece were negative and significantly increased, with the maximum increase rate of 54.88%.The cutting force was greatly reduced, and Fx and Fy decreased by 31.6% and 45.33%, respectively. The instantaneous cutting temperature was also greatly reduced, the maximum reduction of which is 17.53%. With the increase of ultrasonic amplitude and feed per tooth, the surface residual compressive stress increases gradually but decreases with the increase of spindle speed and curvature. The experimental results show that ultrasonic longitudinal-torsional composite milling is a reliable method for machining titanium alloy curved thin-walled parts, which can obtain larger residual compressive stress and improve the machined surface integrity.
Tài liệu tham khảo
E.O. Ezugwu, Z.M. Wang Titanium alloys and their machinability—a review[J]. Journal of Materials Processing Tech, 1997, 68(3):262–274
Li A, Zhao J, Luo H, Pei Z, Wang Z (2012) Progressive tool failure in high-speed dry milling of Ti-6Al-4V alloy with coated carbide tools[J]. Int J Adv Manuf Technol 58(5-8)
Zoya ZA, Krishnamurthy R (2000) The performance of CBN tools in the machining of titanium alloys[J]. Journal of Materials Processing Tech 100(1)
Zhu Z, Guo K, Sun J, Li J, Yang L, Chen L, Zheng Y (2018) Evolution of 3D chip morphology and phase transformation in dry drilling Ti6Al4V alloys[J]. J Manuf Process 34:531–539
Han X, Zhang D (2020) Effects of separating characteristics in ultrasonic elliptical vibration assisted milling on cutting force, chip, and surface morphologies[J]. Int J Adv Manuf Technol 108(5)
Jiang Z, Wang L, Shi L, Yueying W (2014) Study on tool wear mechanism and characteristics of carbide tools in cutting Ti6Al4V[J]. Journal of Mechanical Engineering 50(1):178–184 (in chinese)
Xiong Q, Song G, Zhao W (2013) Cutting technology development of titanium alloy aircraft structural part [J]. Aviation Manufacturing Technology 14:42–47
Dong Y, Liu Z, Ren X, Zhuang P (2016) Hybrid modeling with finite element and statistical methods for residual stress prediction in peripheral milling of titanium alloy Ti-6Al-4V[J]. Int J Mech Sci:108–109
Jiao F, Niu Y, Zhao B (2017) Research progress of residual stress in milling of difficult-to-machine materials [J]. Surface Technology 3:267–273 (in chinese)
Brinksmeier E, Cammett JT, König W, Leskovar P, Peters J, Tönshoff HK (1982) Residual stresses — measurement and causes in machining processes [J]. CIRP Ann Manuf Technol 31(2):491–510
Sun J, Guo YB (2009) A comprehensive experimental study on surface integrity by end milling Ti-6AL-4V[J]. J Mater Process Technol 209(8):4036–4042
Puerta Velásquez JD, Tidu A, Bolle B, Chevrier P, Fundenberger J-J (2010) Sub-surface and surface analysis of high speed machined Ti–6Al–4V alloy[J]. Materials Science & Engineering A 527(10-11):2572–2578
Cong J, Mo R, Wu B, Wang J (2019) Prediction of deformation induced by residual stress in milling of thin-walled part and optimization of cutting parameters [J]. Mech Sci Technol Aerosp Eng, 38(02):205–210 (in Chinese)
Zhou JZ, Huang S, Zuo LD, Meng XK, Sheng J, Tian Q, Han YH, Zhu WL (2014) Effects of laser peening on residual stresses and fatigue crack growth properties of Ti-6Al-4V titanium alloy[J]. Opt Lasers Eng 52(3):189–194
Li C, Zhang F, Meng B, Liu L, Rao X (2017) Material removal mechanism and grinding force modelling of ultrasonic vibration assisted grinding for SiC ceramics[J]. Ceram Int 43(3):2981–2993
Shen X, Zhang J, Xing D, Zhao Y (2012) A study of surface roughness variation in ultrasonic vibration-assisted milling. Int J Adv Manuf Technol 58:553–561
Travieso-Rodriguez JA, Gomez-Gras G, Dessein G, Carrillo F, Alexis J, Jorba-Peiro J, Aubazac N (2015) Effects of a ball-burnishing process assisted by vibrations in G10380 steel specimens. Int J Adv Manuf Technol 81:1757–1765
Zhang X, Zheng K, Liao W, Yao J, Ma W (2017) Investigation on surface integrity for ultrasonic vibration assisted milling titanium alloy [J]. Tool Technology 9(5) (in chinese)
Zhu Y, Wang K, Li L, Huang Y (2009) Evaluation of an ultrasound- aided deep rolling process for anti-fatigue applications[J]. J Mater Eng Perform 18(8):1036–1040
Tong J, Zhao J, Chen P, Zhang Z, Zhao B (2020) Effect of ultrasonic longitudinal–torsional composite milling of the residual stress on the surface of titanium alloy[J]. Proc Inst Mech Eng C J Mech Eng Sci 234(8)
Maurotto A, Wickramarachchi CT (2016) Experimental investigations on effects of frequency in ultrasonically-assisted end-milling of AISI 316L: A feasibility study[J]. Ultrasonics 65:113–120
Niu Y, Jiao F, Zhao B, Tong J (2019) Experiment of machining induced residual stress in longitudinal torsional ultrasonic assisted milling of Ti-6Al-4V [J]. Surface Technology (10):41–51 (in chinese)
Roy S, Jagadish (2017) Design of a circular hollow ultrasonic horn for USM using finite element analysis[J]. Int J Adv Manuf Technol 93(1-4)
Tong J, Wei G, Zhao L, Wang X, Ma J (2018) Surface microstructure of titanium alloy thin-walled parts at ultrasonic vibration-assisted milling. Int J Adv Manuf Technol 101:1007–1021
Dong G, Lang C, Li C, Zhang L (2020) Formation mechanism and modelling of exit edge-chipping during ultrasonic vibration grinding of deep-small holes of microcrystalline-mica ceramics[J]. Ceram Int 46(8):12458–12469