Modeling and experimental study of surface generation in ultrasonic vibration-assisted grinding of Ti-6Al-4V micro-channels

The precision machining of Ti-6Al-4V (TC4) micro-channels remains a challenge due to the poor surface integrity and limited tool life. Ultrasonic vibration-assisted grinding (UVAG) is a promising technique that is being employed to enhance the achieved quality of Ti-6Al-4V micro-channels. Taking the...

Full description

Saved in:
Bibliographic Details
Published in:International journal of advanced manufacturing technology 2024-08, Vol.133 (7-8), p.3801-3818
Main Authors: Zhao, Jing, Zhang, Quanli, Zhang, Yinwu, Zhu, Yandan, Zeng, Zhaoqi, Yang, Changyong, Chen, Yan
Format: Article
Language:English
Subjects:
CAE) and Design
Computer-Aided Engineering (CAD
Cutting wear
Engineering
Grinding wheels
Industrial and Production Engineering
Kinematics
Mechanical Engineering
Media Management
Microchannels
Original Article
Precision machining
Prediction models
Process parameters
Simulation models
Springback
Surface properties
Surface roughness
Titanium base alloys
Tool life
Topography
Ultrasonic vibration
Wear mechanisms
Workpieces
Citations: Items that this one cites
Online Access:Get full text
Tags: Add Tag
No Tags, Be the first to tag this record!
Description
Summary:The precision machining of Ti-6Al-4V (TC4) micro-channels remains a challenge due to the poor surface integrity and limited tool life. Ultrasonic vibration-assisted grinding (UVAG) is a promising technique that is being employed to enhance the achieved quality of Ti-6Al-4V micro-channels. Taking the wheel’s wear and the springback of the workpiece into consideration, a new kinematic simulation model for the 3D surface generation process is first developed, and the material removal mechanism under different ultrasonic parameters during UVAG of Ti-6Al-4V is investigated based on the calculated grit-cutting trajectory and ground surface topography. Comparing the simulated and experimental results, it is found that the built surface topography prediction model can successfully capture the obtained surface characteristics of Ti-6Al-4V by CG and UVAG process. The condition for intermittent machining in UVAG is obtained by establishing the mathematical relation between grinding and ultrasonic parameters. Therefore, the model developed in this paper can be applied to predict surface roughness and optimize the UVAG process of Ti-6Al-4V.
ISSN:0268-3768
1433-3015
DOI:10.1007/s00170-024-13946-5