Research On Simulation And Surface Properties Of Ultrasonic Vibration Assisted Milling

The position of new materials become more and more prominent in the market with the rapid development of science and technology.The urgent demand for new materials with high performance is also reflected in aerospace,navigation,electronics,national defense and some other modern industries.These new materials are characterized by high stress strain,high hardness,high brittleness,wear resistance and corrosion resistance which could be able to adapt to the performance of modern highly sophisticated products.Although these materials have good mechanical properties,a great challenge are also brought to the traditional manufacturing industry.New manufacturing technology are emerging driven by new materials.Ultrasonic vibration assisted machining is an important representative of new manufacturing technology.Ultrasonic vibration assisted machining is a composite machining technology which combines ultrasonic vibration of high frequency and low amplitude with traditional machining technology.According to the mode of vibration,the ultrasonic vibration assisted machining can be classified into one-dimensional ultrasonic vibration assisted machining and two-dimensional ultrasonic vibration assisted machining.Ultrasonic vibration changed the contact way between tool and workpiece,the cutting force and surface quality were improved to some extent.The surface will be machined some regular surface micro textures by the tool with high frequency harmonic motion.These surface textures have great differences with the processing parameters and vibration parameters.Surface texture also have great influence on surface properties.In this paper,the process of ultrasonic vibration assisted milling and the morphology and properties of machined surface were analyzed by means of finite element simulation and experimental research.The kinematic and dynamic analysis of ultrasonic vibration assisted milling were carried out.The cutting process simulation were realized by FEM software ThirdWave AdvantEdge,including cutting parameters,material constitutive model,damage model and contact model between tool and chip.The results showed competitive results for strain,stress,temperature and cutting force when compared with traditional machining.The ultrasonic horn is an important component,in order to ensure its stability,model analysis and harmonic response analysis of horn were carried out.The natural frequencies and mode shapes of the horn are obtained by modal analysis.The harmonic response analysis is carried out to study the steady state response of the system under the condition of ultrasonic vibration load,and the displacement response of the end face is extracted.Experimental study on ultrasonic vibration assisted milling of aluminum alloy 2A12,steel and titanium alloy Ti-6A1-4V.The effects of spindle speed,feed per tooth and amplitude of ultrasonic vibration on cutting force and surface quality were studied.In order to study the effect of ultrasonic vibration assisted milling on surface morphology,the microscope and scanning electron microscope equipment were used to analyze the surface morphology.The results showed that the formation of different surface textures can be fabricated by changing the parameters.The effects of spindle speed,feed per tooth and amplitude on surface texture were analyzed.Surface texture has a great influence on surface properties.Different surface textures could be obtained by ultrasonic vibration assisted milling.In order to study the effect of surface texture on the surface properties,the machined surface of titanium alloy Ti-6A1-4V was investigated.The surface properties such as hydrophobic properties,friction and wear resistance are important properties of the surface,especially in the modern industry.Therefore,the hydrophobic properties and tribological properties of surface textures under different processing parameters were studied.The contact angle experiment and the friction and wear test were both carried out.The contact angle experiment mainly studied the contact angle of water,the friction and wear experiments were classified into dry friction and grease friction.At the same time,in order to study the relationship between surface texture and surface properties,the variation of contact angle,friction coefficient with respect to surface roughness were analyzed.Surface drag reduction is an important property of surface.The model of micro surface morphology was built and the surface flow field was analyzed.