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<p>Ti6Al4V has garnered significant interest from the high-end manufacturing industry due to its exceptional mechanical properties, superior heat resistance, and excellent corrosion resistance. Nevertheless, the material’s ultra-high strength and low thermal conductivity pose significant challenges to the precision machining of titanium alloys. Elliptical vibration cutting (EVC) emerges as an effective technique to enhance the machinability of these alloys. However, the workpiece is impacted by the tool in terms of the vibration trajectory and time-varying cutting speed during the interaction between the workpiece and the tool, which makes the local deformation characteristics of the material unique. Describing the geometric characteristics of material deformation quantitatively during actual machining is challenging. Consequently, the finite element method (FEM) is employed to characterize the material’s deformation by measuring the normal and oblique shear angles through the stress distribution in the primary shear zone and the direction of the shear force on the shear plane. This paper investigates the variation laws and characteristics of the normal shear angle, oblique shear angle, and cutting force for orthogonal EVC and EVC of orthogonal modulation with an oblique angle of Ti6Al4V alloy, using vibration frequency, vibration amplitude, and speed ratio as variables, based on FEM. The cutting characteristics of the two methods are elucidated, and the findings provide crucial insights for uncovering the material deformation mechanism and optimizing process parameters to enhance machining quality.</p>

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Finite element investigation on shear deformation and cutting force for two types of elliptical vibration cutting Ti6Al4V alloy

  • 期刊论文

  • 发表日期：

    2025年6月3日

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  • Zongzheng Zhou,
  • Jinguo Han,
  • Shunkang Li,
  • Zeqi Feng,
  • Xinzhe Han,
  • Xianfu Liu,
  • Yanhou Liu

摘要

Ti6Al4V has garnered significant interest from the high-end manufacturing industry due to its exceptional mechanical properties, superior heat resistance, and excellent corrosion resistance. Nevertheless, the material’s ultra-high strength and low thermal conductivity pose significant challenges to the precision machining of titanium alloys. Elliptical vibration cutting (EVC) emerges as an effective technique to enhance the machinability of these alloys. However, the workpiece is impacted by the tool in terms of the vibration trajectory and time-varying cutting speed during the interaction between the workpiece and the tool, which makes the local deformation characteristics of the material unique. Describing the geometric characteristics of material deformation quantitatively during actual machining is challenging. Consequently, the finite element method (FEM) is employed to characterize the material’s deformation by measuring the normal and oblique shear angles through the stress distribution in the primary shear zone and the direction of the shear force on the shear plane. This paper investigates the variation laws and characteristics of the normal shear angle, oblique shear angle, and cutting force for orthogonal EVC and EVC of orthogonal modulation with an oblique angle of Ti6Al4V alloy, using vibration frequency, vibration amplitude, and speed ratio as variables, based on FEM. The cutting characteristics of the two methods are elucidated, and the findings provide crucial insights for uncovering the material deformation mechanism and optimizing process parameters to enhance machining quality.