JZUS - Journal of Zhejiang University SCIENCE

Journal of Zhejiang University SCIENCE A

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High-performance milling of Ti-6Al-4V through rotary ultrasonic elliptical milling with anticlockwise elliptical vibration

Author(s): Lianxing LIU, Xinggang JIANG, Enze YING, Zhefei SUN, Daxi GENG, Deyuan ZHANG
Affiliation(s): School of Mechanical Engineering and Automation, Beihang University, Beijing 100191, China; more
Corresponding email(s): gengdx@buaa.edu.cn, zhangdy@buaa.edu.cn
Key Words: Ultrasonic elliptical vibration cutting (UEVC); Vibration direction; Rotary ultrasonic elliptical machining (RUEM); Surface formation mechanism; Surface integrity; High-speed milling

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Lianxing LIU, Xinggang JIANG, Enze YING, Zhefei SUN, Daxi GENG, Deyuan ZHANG. High-performance milling of Ti-6Al-4V through rotary ultrasonic elliptical milling with anticlockwise elliptical vibration[J]. Journal of Zhejiang University Science A,in press.Frontiers of Information Technology & Electronic Engineering,in press.https://doi.org/10.1631/jzus.A2500007

@article{title="High-performance milling of Ti-6Al-4V through rotary ultrasonic elliptical milling with anticlockwise elliptical vibration",
author="Lianxing LIU, Xinggang JIANG, Enze YING, Zhefei SUN, Daxi GENG, Deyuan ZHANG",
journal="Journal of Zhejiang University Science A",
year="in press",
publisher="Zhejiang University Press & Springer",
doi="https://doi.org/10.1631/jzus.A2500007"
}

%0 Journal Article
%T High-performance milling of Ti-6Al-4V through rotary ultrasonic elliptical milling with anticlockwise elliptical vibration
%A Lianxing LIU
%A Xinggang JIANG
%A Enze YING
%A Zhefei SUN
%A Daxi GENG
%A Deyuan ZHANG
%J Journal of Zhejiang University SCIENCE A
%P 707-722
%@ 1673-565X
%D in press
%I Zhejiang University Press & Springer
doi="https://doi.org/10.1631/jzus.A2500007"

TY - JOUR
T1 - High-performance milling of Ti-6Al-4V through rotary ultrasonic elliptical milling with anticlockwise elliptical vibration
A1 - Lianxing LIU
A1 - Xinggang JIANG
A1 - Enze YING
A1 - Zhefei SUN
A1 - Daxi GENG
A1 - Deyuan ZHANG
J0 - Journal of Zhejiang University Science A
SP - 707
EP - 722
%@ 1673-565X
Y1 - in press
PB - Zhejiang University Press & Springer
ER -
doi="https://doi.org/10.1631/jzus.A2500007"

Abstract
Chinese Summary
Academic Network
Reviewer Comment

Abstract: Ultrasonic elliptical vibration cutting (UEVC) with clockwise elliptical vibration has made notable achievements in precision machining; however, its critical cutting speed limits its application to low-speed machining tasks. Meanwhile, rotary ultrasonic elliptical machining (RUEM) with clockwise elliptical vibration has been validated as an effective high-speed cutting technology. Unfortunately, conventional RUEM leads to increased surface roughness. To address this issue and enhance machining quality, we propose a novel RUEM method employing an anticlockwise vibration direction, called anticlockwise rotary ultrasonic elliptical machining (ARUEM). The mechanisms of surface formation and subsurface strengthening for ARUEM are analyzed. Experimental validations were performed on Ti-6Al-4V alloy, revealing that ARUEM achieved substantially lower ridge heights and up to a 50% reduction in surface roughness compared to conventional RUEM. Additionally, relative to conventional milling, ARUEM resulted in up to 122.6% thicker plastic deformation layers, 53.4% higher surface residual compressive stress, and 19.3% greater surface micro-hardness. This study showcases a promising method for high-performance milling of Ti-6Al-4V, offers new insights into RUEM by examining the influence of vibration direction, and enhances understanding of surface formation and subsurface strengthening in the ARUEM method.

基于逆时针椭圆振动的钛合金旋转超声椭圆铣削高性能加工方法

作者：刘连星^1,2，姜兴刚^1,2，应恩泽^1,2，孙哲飞^1,2，耿大喜^1,2，张德远^1,2
机构：¹北京航空航天大学，机械工程及自动化学院，中国北京，100191；²北京航空航天大学，仿生与微纳系统研究所，中国北京，100191
目的：针对顺时针旋转超声椭圆加工（CRUEM）中表面粗糙度较高的问题，本文提出一种逆时针椭圆振动方向的旋转超声椭圆加工（ARUEM）方法，旨在探究ARUEM的表面形成与亚表层强化机理，以提升钛合金（Ti-6Al-4V）铣削的表面质量和加工性能。
创新点：1.提出逆时针椭圆振动方向的新型旋转超声椭圆加工方法（ARUEM），揭示其表面形成机制；2.通过运动学分析与实验验证，阐明振动方向对表面粗糙度、残余应力和微观硬度的调控作用。
方法：1.建立ARUEM与CRUEM的刀具运动轨迹模型，推导切削速度与加速度的周期性变化规律（图S1和S2）；2.结合仿真与实验，分析表面形貌、残余应力、塑性变形层及微观硬度（图10~15）；3.通过对比不同振动幅值与切削速度下的加工效果，验证ARUEM的优化潜力。
结论：1.相较于CRUEM，ARUEM通过修正刀具轨迹降低表面残余高度，使表面粗糙度最大可降低50%；2. ARUEM显著提升表面完整性，使塑性变形层厚度、残余压应力和表面显微硬度分别提高122.6%、53.4%和19.3%；3. ARUEM在保留CRUEM间歇切削优势的同时，为对表面粗糙度要求严格的难加工材料强化场景提供了有效的新手段。

关键词组：超声椭圆振动切削；振动方向；旋转超声椭圆加工；表面形成机制；表面完整性；高速铣削

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基于逆时针椭圆振动的钛合金旋转超声椭圆铣削高性能加工方法

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