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<p>Ti<sub>2</sub>AlNb intermetallic alloy is a typical high-temperature resistant material with exceptional mechanical properties and is beneficial to enhance the performance of aero-engine components. However, machining of Ti<sub>2</sub>AlNb intermetallic alloy is extremely difficult, and ensuring the required surface integrity is an ongoing challenge, especially when aiming to preserve surface defects for high-precision applications. The benefits of ultrasonic-assisted machining in enhancing machinability are well documented. However, the precise impact of longitudinal ultrasonic vibration–assisted milling (LUVAM) on the material removal mechanism and surface quality in Ti<sub>2</sub>AlNb intermetallic alloy machining is yet uncertain, highlighting a crucial area for comprehensive research. Therefore, this work presents in-depth theoretical investigations into the material removal mechanism, surface generation mechanism, and tool-chip separation conditions associated with LUVAM. Then, conventional milling (CM) and LUVAM experiments on Ti<sub>2</sub>AlNb were performed, and the study encompasses the analysis of cutting forces, chip morphology, surface defects, and texture characteristics using a scanning electron microscope (SEM) and morphological assessment. The results reveal that LUVAM reduces the <i>F</i><sub>x</sub> and <i>F</i><sub>y</sub> cutting forces compared with CM, while the reduction in cutting forces progressively decreases with increasing cutting speed. The longitudinal vibration in LUVAM assists in chip breakage and the formation of thinner lamellae on chip-free surfaces as compared with CM. The utilization of LUVAM leads to the formation of ultrasonic vibration texture on the chip back surface and machined surface and suppresses the formation of grooves and material adhesion, which are prominent in CM. In addition, LUVAM is beneficial in reducing surface roughness and causes a maximum reduction of 21.43% and 20.6% in 3D surface roughness <i>S</i><sub>a</sub> and <i>S</i><sub>q</sub>, respectively, compared with the CM. Furthermore, these insights into material removal mechanism, chip formation, and surface quality in LUVAM of Ti<sub>2</sub>AlNb intermetallic alloy not only advance the understanding of this process but also lay the groundwork for further optimization in high-performance aerospace and engineering applications, where superior surface integrity is paramount.</p>

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Unraveling the influence of vibrations on material removal and surface quality in longitudinal ultrasonic vibration–assisted milling of Ti2AlNb intermetallic alloy

  • 期刊论文

  • 发表日期：

    2025年1月9日

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  • Ahmar Khan,
  • Qingliao He,
  • Xin Wang,
  • Biao Zhao,
  • Wenfeng Ding,
  • Aqib Mashood Khan,
  • Syed Hammad Ali,
  • Sadam Hussain

摘要

Ti2AlNb intermetallic alloy is a typical high-temperature resistant material with exceptional mechanical properties and is beneficial to enhance the performance of aero-engine components. However, machining of Ti2AlNb intermetallic alloy is extremely difficult, and ensuring the required surface integrity is an ongoing challenge, especially when aiming to preserve surface defects for high-precision applications. The benefits of ultrasonic-assisted machining in enhancing machinability are well documented. However, the precise impact of longitudinal ultrasonic vibration–assisted milling (LUVAM) on the material removal mechanism and surface quality in Ti2AlNb intermetallic alloy machining is yet uncertain, highlighting a crucial area for comprehensive research. Therefore, this work presents in-depth theoretical investigations into the material removal mechanism, surface generation mechanism, and tool-chip separation conditions associated with LUVAM. Then, conventional milling (CM) and LUVAM experiments on Ti2AlNb were performed, and the study encompasses the analysis of cutting forces, chip morphology, surface defects, and texture characteristics using a scanning electron microscope (SEM) and morphological assessment. The results reveal that LUVAM reduces the Fx and Fy cutting forces compared with CM, while the reduction in cutting forces progressively decreases with increasing cutting speed. The longitudinal vibration in LUVAM assists in chip breakage and the formation of thinner lamellae on chip-free surfaces as compared with CM. The utilization of LUVAM leads to the formation of ultrasonic vibration texture on the chip back surface and machined surface and suppresses the formation of grooves and material adhesion, which are prominent in CM. In addition, LUVAM is beneficial in reducing surface roughness and causes a maximum reduction of 21.43% and 20.6% in 3D surface roughness Sa and Sq, respectively, compared with the CM. Furthermore, these insights into material removal mechanism, chip formation, and surface quality in LUVAM of Ti2AlNb intermetallic alloy not only advance the understanding of this process but also lay the groundwork for further optimization in high-performance aerospace and engineering applications, where superior surface integrity is paramount.