Research on Milling Deformation in Ultrasonic Vibration Assisted End Milling of Titanium Alloy Thin-Walled Parts

2018 ◽  
Vol 764 ◽  
pp. 174-183
Author(s):  
Feng Jiao ◽  
Li Zhao ◽  
Cheng Lin Yao ◽  
Feng Qi
Keyword(s):  
Titanium Alloy ◽  
Ultrasonic Vibration ◽  
End Milling ◽  
Orthogonal Experiment ◽  
Machining Accuracy ◽  
Thin Wall ◽  
Range Analysis ◽  
Milling Parameters ◽  
Alloy Material ◽  
Thin Walled

The hard machinability of titanium alloy material and the poor stiffness of thin-walled parts hindered the extensive application of titanium alloy thin-walled components in aerospace engineering. In order to heighten the geometric accuracy in the processing, the ultrasonic vibration assisted (UVA) end milling technology with workpiece vibrating in feed direction was put forward in this paper, and characteristics of the milling deformation in UVA milling of titanium alloy TC4 thin-walled workpieces were researched. Through the theoretical analysis, the cutting force and deformation characteristics in UVA milling were clarified. Based on the range analysis of orthogonal experiment, the effects of milling parameters and ultrasonic amplitude on the deflection displacement and the milling deformation of workpieces are obtained. Research results show that the deflection displacement in the process of UVA milling affects the thickness error of the thin wall. Ultrasonic parameters as well as milling parameters should be optimized to obtain higher machining accuracy. The research provides a certain reference for the precision milling of titanium alloy thin-walled parts.

Research on Milling Force in Ultrasonic Assisted End Milling of Titanium Alloy Thin-Walled Parts

2018 ◽  
Vol 764 ◽  
pp. 252-260
Author(s):  
Feng Jiao ◽  
Cheng Lin Yao ◽  
Li Zhao ◽  
Feng Qi
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
End Milling ◽  
Signal To Noise Ratio ◽  
Milling Force ◽  
Alloy Material ◽  
Ultrasonic Assisted ◽  
Thin Walled ◽  
Force Characteristics

Hard machinability of titanium alloy material and poor stiffness of thin-walled part restricted the extensive applications of titanium alloy thin-walled component in aerospace engineering. In order to increase geometric accuracy, a method of ultrasonic vibration assisted (UVA) end milling technology with workpiece vibrating in feeding direction was put forward in this paper, and the corresponding milling force characteristics in UVA milling of titanium alloy TC4 thin-walled workpiece were researched. Through theoretical analysis, the path of cutter tooth in UVA milling was analyzed. The important factors that affect milling force are obtained with the signal to noise ratio analysis. Results show that the radial cutting force in UVA milling is smaller than that in traditional milling. Cutting force fluctuate in high frequency when treated ultrasonic vibration. And the axial cutting feed is the core factor that affects the milling force. The research provides a certain reference for the precision milling of titanium alloy thin-walled parts.

Investigation of the Milling Performance about Titanium Alloy Based on Orthogonal Experiment

2010 ◽  
Vol 44-47 ◽  
pp. 2867-2871
Author(s):  
Ke Yan Tang ◽  
Li Hua Zhou ◽  
Li Song
Keyword(s):  
Titanium Alloy ◽  
Orthogonal Experiment ◽  
Milling Process ◽  
Machining Accuracy ◽  
Milling Force ◽  
Milling Parameters ◽  
Milling Performance ◽  
Orthogonal Experiments ◽  
Ta15 Titanium Alloy ◽  
Single Factor Experiment

The milling process has been widely used for manufacturing aeronautical materials. It is very important to choose the reasonable milling parameters for improving the machining accuracy and surface quality. In this paper, the orthogonal experiments are made to construct the relationships between the milling force and milling parameters to TA15 titanium alloy. And the milling parameters mainly include milling speed, milling depth, milling width and feed engagement. And the empirical equations of milling force are gotten by regression analysis, and the equations are tested to be correct by the single factor experiment. The result is quite important for further research on the milling performance and can serve as a reference to production of titanium alloys.

scholarly journals Experimental Analysis and Prediction Model of Milling-Induced Residual Stress of Aeronautical Aluminum Alloys

2021 ◽  
Vol 11 (13) ◽  
pp. 5881
Author(s):  
Shouhua Yi ◽  
Yunxin Wu ◽  
Hai Gong ◽  
Chenxi Peng ◽  
Yongbiao He
Keyword(s):  
Residual Stress ◽  
Aluminum Alloy ◽  
Prediction Model ◽  
End Milling ◽  
Orthogonal Experiment ◽  
7075 Aluminum Alloy ◽  
Side Milling ◽  
Milling Parameters ◽  
Thin Walled ◽  
Machining Deformation Prediction

Aeronautical thin-walled frame workpieces are usually obtained by milling aluminum alloy plates. The residual stress within the workpiece has a significant influence on the deformation due to the relatively low rigidity of the workpiece. To accurately predict the milling-induced residual stress, this paper describes an orthogonal experiment for milling 7075 aluminum alloy plates. The milling-induced residual stress at different surface depths of the workpiece, without initial stress, is obtained. The influence of the milling parameters on the residual stress is revealed. The parameters include milling speed, feed per tooth, milling width, and cutting depth. The experimental results show that the residual stress depth in the workpiece surface is within 0.12 mm, and the residual stress depth of the end milling is slightly greater than that of the side milling. The calculation models of residual stress and milling parameters for two milling methods are formulated based on regression analysis, and the sensitivity coefficients of parameters to residual stress are calculated. The residual stress prediction model for milling 7075 aluminum alloy plates is proposed based on a back-propagation neural network and genetic algorithm. The findings suggest that the proposed model has a high accuracy, and the prediction error is between 0–14 MPa. It provides basic data for machining deformation prediction of aluminum alloy thin-walled workpieces, which has significant application potential.

Based on the Titanium Alloy Milling Forces Modeling and Simulation Study

2014 ◽  
Vol 1004-1005 ◽  
pp. 1231-1235
Author(s):  
Yi Rong Zhang ◽  
Hou Jun Qi
Keyword(s):  
Titanium Alloy ◽  
Mechanical Model ◽  
End Milling ◽  
Orthogonal Experiment ◽  
Milling Force ◽  
Mechanics Model ◽  
Alloy Material ◽  
Experiment Method ◽  
Orthogonal Experiment Method ◽  
Milling Forces

A common mechanical model of ball-end milling cutter is analyzed in this paper, and take advantage of the orthogonal experiment method to make experiment of milling to identify the milling force coefficients with the titanium alloy material as the test object.Then put the coefficients in the mechanical model of ball to use MATLAB software to predict the milling force. The results of experiment and results of simulation are basically identical, it shows that the mechanics model of ball milling is proved to be correct.

Experiment Study on Deflection of Aluminum Alloy Thin-Wall Workpiece in Milling Process

2011 ◽  
Vol 697-698 ◽  
pp. 129-132 ◽  
Author(s):  
Bing Han ◽  
Cheng Zu Ren ◽  
X.Y. Yang ◽  
Guang Chen
Keyword(s):  
Aluminum Alloy ◽  
Coordinate Measuring Machine ◽  
Milling Process ◽  
Cnc Machining ◽  
Machining Accuracy ◽  
Thin Wall ◽  
Machining Center ◽  
Machining Errors ◽  
Alloy Material ◽  
Measuring Machine

The deflection of Aluminum alloy thin-wall workpiece caused by the milling force leads to additional machining errors and reduces machining accuracy. In this paper, a set of experiments of milling thin-wall workpiece were carried out to study the deflection of thin-wall workpiece. The workpieces, with different types of material and different thicknesses, were machined on CNC machining center. The deflections of workpiece were measured by a three-coordinate measuring machine. Effects of Aluminum alloy material and thickness on deflection are discussed based on the experimental data.

Research on Finite Element Simulation and Parameters Optimization of Milling 7050-T7451 Aluminum Alloy Thin-walled Parts

2020 ◽  
Vol 14 ◽  
Author(s):  
Song Yang ◽  
Tie Yin ◽  
Feiyue Wang
Keyword(s):  
Aluminum Alloy ◽  
Complex Structure ◽  
Parameters Optimization ◽  
Thin Wall ◽  
Machining Parameters ◽  
Milling Parameters ◽  
Machining Deformation ◽  
Milling Temperature ◽  
Thin Walled ◽  
Milling Forces

Background: Thin-walled parts of aluminum alloy are easy to occur machining deformation duo to the characteristics of thin wall, low rigidity, and complex structure. Objective: To reduce and control the machining deformation, it is necessary to select reasonable machining parameters. Method: The influence of milling parameters on the milling forces, milling temperature, and machining deformation was analyzed through the established model based on ABAQUS. Then, the corresponding empirical formula was obtained by MATLAB, and parameters optimization was carried out as well. Besides, a lot of patents on machining thin-walled parts were studied. Results: The results shown that the prediction error of milling forces is about 15%, and 20% of milling temperature. In this case, the optimized milling parameters are as follows: ap=1 mm, ae=0.1 mm, n=12 000 r/min, and f=400 mm/min. It is of great significance to reduce the machining deformation and improve the machining quality of thin-walled parts.

Removal Mechanism of Titanium Alloy Material in Ultrasound Vibration Drilling

2020 ◽  
Vol 993 ◽  
pp. 3-11
Author(s):  
Tian Qi Wang ◽  
Zhan Feng Liu ◽  
Yuan Ying Qiu ◽  
Ya Zhou Feng ◽  
Xiao Lan Han
Keyword(s):  
Titanium Alloy ◽  
Ultrasonic Vibration ◽  
Removal Rate ◽  
Small Diameter ◽  
Simulation Software ◽  
Drilling Process ◽  
Element Simulation ◽  
Alloy Material ◽  
The Difference ◽  
Vibration Drilling

In drilling the ultra-slim small diameter deep hole of titanium alloy, the problem of chip breaking and chip removal is common. When the drill is working normally, the ultrasonic vibration can be applied for the drill bit to cut the bit in the vibration to form a pulse. The cutting force waveform in drilling, should select the reasonable vibration frequency, amplitude, feed amount, workpiece rotation and other parameters to match, control the size and shape of the chip, get satisfactory chips, and avoid chip clogging. In this study, the ANSYS finite element simulation software was used to simulate the TC4 drilling process, and the difference between ultrasonic vibration drilling and ordinary drilling was analyzed. Drilling experiments were carried out. The experimental results show that compared with conventional drilling, ultrasonic vibration drilling has better surface quality, reduced tool wear and increased material removal rate.

Experimental Analysis of Damping Fixture for Thin-Walled Workpiece Milling

2016 ◽  
Vol 836-837 ◽  
pp. 296-303
Author(s):  
Dong Sheng Liu ◽  
Ming Luo ◽  
Ding Hua Zhang
Keyword(s):  
Manufacturing Industry ◽  
Machining Process ◽  
Machining Accuracy ◽  
Thin Wall ◽  
Machining Parameters ◽  
System Parameters ◽  
Thin Walled Structures ◽  
Machining System ◽  
Machining Test ◽  
Thin Walled

Thin-walled workpieces are widely used in the aerospace manufacturing industry in order to reduce the weight of structure and improve working efficiency. However, vibration is easy to occur in machining of thin-walled structures due to its low stiffness. Machining vibration will result in lower machining accuracy as well as machining efficiency. In order to reduce the machining vibrations of thin-wall workpieces, commonly used method is to select proper machining parameters according to the chatter stability lobes, which is generated according to the machining system parameters. However, this method requires exact system parameters to be determined, which are always changing in the machining process. In this paper, a special designed fixture with damping materials for the thin-walled workpiece is presented based on the machining vibration control theory, and analysis of the effect of vibration suppressing is obtained through the contrast of vibration tests of milling the thin-walled workpiece on the damping clamp. The damping material is used to consume vibration energy and provide support for thin-walled structure. Machining test was carried out for thin-walled structure machining to validate the effectiveness of the proposed method.

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