Study on Longitudinal-Bending Hybrid Ultrasonic Vibration Milling Device and Machining Performance of TC4 Titanium Alloy
ZHANG Junjie 1 , LIU Yingxiang 2 , HU Wangjie 1 , DU Pengfei 2 , HAN La 1 , DENG Jie 2 , QIU Xu 1 , ZHAO Xuesen 1 , HU Zhenjiang 1 , SUN Tao 1
1. Center for Precision Engineering, Harbin Institute of Technology, Harbin 150001, China;
2. State Key Laboratory of Robotics and System, Harbin Institute of Technology, Harbin 150001, China
Abstract：TC4 titanium alloy has been widely used in aviation and aerospace industry because of its excellent comprehensive mechanical properties. However, the high plasticity and low thermal conductivity of TC4 lead to pronounced tool-chip adhesion, which is a key factor restricting the improvement of its milling performance. In this paper, a longitudinal-bending hybrid ultrasonic vibration assisted milling method is proposed to improve the milling performance of TC4, through the reduction of tool-chip adhesion accompanied by the controllable intermittent cutting realized by individually controlling the amplitude and phase of longitudinal and bending ultrasonic vibration of the cutting tool. Firstly, the kinematics principle of longitudinal-bending hybrid ultrasonic vibration assisted milling is analyzed theoretically. Based on this, the longitudinal-bending hybrid ultrasonic vibration tool is designed and manufactured. After assembly of the vibration tool with the high-speed spindle, the radial runout of the milling tool is less than 20μm. Then, a three-axis linkage equipment of longitudinal-bending hybrid ultrasonic vibration assisted milling is established, with which the vibration-assisted milling experiments of TC4 are carried out, and the experimental results are characterized and analyzed. The experimental results show that the applying of longitudinal-bending hybrid ultrasonic vibration to conventional milling effectively reduces the cutting force, the burr generation and the tool wear, while improving the surface machining quality, which demonstrate the feasibility of applying the longitudinal-bending hybrid ultrasonic vibration assisted milling in improving the milling performance of TC4 titanium alloy.
2022, 
