Modeling of cutting forces in 1-D and 2-D ultrasonic vibration-assisted milling of Ti-6Al-4V

Philipp M. Rinck, Alpcan Gueray, Michael F. Zaeh

Research output: Contribution to journalArticlepeer-review

7 Scopus citations

Abstract

To meet the modern demands for lightweight construction and energy efficiency, hard-to-machine materials such as ceramics, superalloys, and fiber-reinforced plastics are being used progressively. These materials can only be machined with great effort using conventional machining processes due to the high cutting forces, poor surface qualities, and the associated tool wear. Vibration-assisted machining has already proven to be an adequate solution in order to achieve extended tool lives, better surface qualities, and reduced cutting forces. This paper presents an analytical force model for longitudinal-torsional vibration-assisted milling (LT-VAM), which can predict cutting forces under intermittent and non-intermittent cutting conditions. Under intermittent cutting conditions, the relative contact ratio between the rake face and the sliding chip is utilized for modelling the shearing forces. Ploughing forces and shearing forces under non-intermittent cutting conditions are calculated by using an extended macroscopic friction reduction model, which can predict the reduced frictional forces under parallel and perpendicular vibration superimposition. The force model was implemented in MATLAB and can predict cutting forces without using any experimental vibration-assisted milling (VAM) data input.

Original languageEnglish
Pages (from-to)1807-1819
Number of pages13
JournalInternational Journal of Advanced Manufacturing Technology
Volume119
Issue number3-4
DOIs
StatePublished - Mar 2022

Keywords

  • Cutting force
  • Friction reduction
  • Milling
  • Ti 6 Al 4V
  • Vibration-assisted machining (VAM)

Fingerprint

Dive into the research topics of 'Modeling of cutting forces in 1-D and 2-D ultrasonic vibration-assisted milling of Ti-6Al-4V'. Together they form a unique fingerprint.

Cite this