Micromachining performance of additively manufactured titanium alloys in synergistic application of ultrasonic elliptical machining and textured tool methods

• Published in: International journal of advanced manufacturing technology 2025, Vol.136 (5), p.2707-2729
• Main Authors: Lu, Wei, Ni, Chenbing, Wang, Youqiang, Zong, Chengguo, Liu, Dejian
• Format: Article
• Language: English
• Subjects: CAE) and Design; Chip formation; Computer-Aided Engineering (CAD; Cutting force; Cutting parameters; Cutting tools; Engineering; Industrial and Production Engineering; Laser beam melting; Machinability; Machining; Mechanical Engineering; Mechanical properties; Media Management; Micromachining; Microtexture; Original Article; Strain; Stress distribution; Surface properties; Temperature distribution; Thickness; Titanium alloys; Titanium base alloys; Trajectories; Ultrasonic vibration; Vibration mode
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-024-14994-7

Post-processing of selective laser melted (SLMed) Ti6Al4V alloy with poor surface quality and low dimensional accuracy is a necessary operation to better achieve its operational performance. Considering the principle and advantages of ultrasonic vibration–assisted machining (UVAM) and textured tools, the synergistic application of UVAM and textured tools is expected to improve the micro-machining performance of SLMed Ti6Al4V alloy. The micro-machinability and machining mechanism of the SLMed Ti6Al4V alloy are investigated by a series of micro-machining with different scanning strategies, different ultrasonic vibration modes, different micro-texture tool types, and different elliptical trajectories. Multifaceted comparisons of machining results are presented in terms of cutting force, cutting temperature, equivalent stress and strain, temperature field, stress field, strain field, and chip formation. The machining results showed that the cutting forces of UVAM are reduced by 56.5 ~ 66.8% compared with conventional machining (CM). The differences in the cutting forces and temperatures of SLMed Ti6Al4V alloys with different scanning strategies are dependent on the microstructures and mechanical properties. The stress and strain fields are significantly affected by the coupled impact effect of cutting motion and ultrasonic vibration, and the UVAM processes improve serrated chip fracture properties. The dual effect of ultrasonic elliptical vibration and textured tools produces better machining performance, especially for the semi-elliptical micro-texture tools. The differences in machining response for different elliptical trajectories are attributed to the effects of tool vibration impact angle and the dynamic cutting thickness, and the machining response with a phase difference of φ  = 45° is better.