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<p>Accurate prediction of burr size is critical to increase milling productivity, reduce costs, and minimize the time required for trials and testing. Although many prediction methods have been developed, less research has been conducted on burr size prediction at the exit of longitudinal torsional ultrasonic vibration-assisted side milling (LTUSM). In this paper, a burr size prediction model for LTUAM of Ti-6Al-4&#xa0;V titanium alloy is proposed, which can be used to predict the height and width of the burr at the exit of LTUAM of Ti-6Al-4&#xa0;V titanium alloy. In this paper, the burr formation mechanism is analyzed, the burr height and width dimensions are predicted, and the effects of process parameters on the burr are explored through theoretical modeling and experiments to reduce the burr dimensions from the source. In addition, the predicted results of the theoretical modeling of burr size were compared with the experimental results. The experimental results show that there is a significant agreement between the observed burr sizes and the predictions derived from the theoretical modeling. The exit burr sizes <i>B</i><sub><i>HE</i></sub> and <i>B</i><sub><i>WE</i></sub> decreased with increasing ultrasonic amplitude, feed per tooth, and cutting speed, and increased with increasing radial depth of cut and tool wear. The trends of the tested and calculated values of the exit burr dimensions <i>B</i><sub><i>HE</i></sub> and <i>B</i><sub><i>WE</i></sub> were the same, and the errors between the tested and theoretically predicted values were within 12%. Specifically, the prediction errors were within 10% for burr height and within 12% for burr width, which fully demonstrated the reliability of the model. The results of the orthogonal tests showed that ultrasonic amplitude, feed per tooth, and tool wear type had a significant effect on the burr exit height. Similarly, ultrasonic amplitude and radial depth of cut were the main factors affecting burr width. These findings emphasize the critical role of specific parameters, highlighting their significant influence on burr formation during machining.</p>

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Modeling and experimental evaluation of exit burrs in longitudinal

  • 期刊论文

  • 发表日期：

    2025年7月12日

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  • Boxi Xue,
  • Mingli Zhao,
  • Wenbin Song,
  • Hao Wang

摘要

Accurate prediction of burr size is critical to increase milling productivity, reduce costs, and minimize the time required for trials and testing. Although many prediction methods have been developed, less research has been conducted on burr size prediction at the exit of longitudinal torsional ultrasonic vibration-assisted side milling (LTUSM). In this paper, a burr size prediction model for LTUAM of Ti-6Al-4 V titanium alloy is proposed, which can be used to predict the height and width of the burr at the exit of LTUAM of Ti-6Al-4 V titanium alloy. In this paper, the burr formation mechanism is analyzed, the burr height and width dimensions are predicted, and the effects of process parameters on the burr are explored through theoretical modeling and experiments to reduce the burr dimensions from the source. In addition, the predicted results of the theoretical modeling of burr size were compared with the experimental results. The experimental results show that there is a significant agreement between the observed burr sizes and the predictions derived from the theoretical modeling. The exit burr sizes BHE and BWE decreased with increasing ultrasonic amplitude, feed per tooth, and cutting speed, and increased with increasing radial depth of cut and tool wear. The trends of the tested and calculated values of the exit burr dimensions BHE and BWE were the same, and the errors between the tested and theoretically predicted values were within 12%. Specifically, the prediction errors were within 10% for burr height and within 12% for burr width, which fully demonstrated the reliability of the model. The results of the orthogonal tests showed that ultrasonic amplitude, feed per tooth, and tool wear type had a significant effect on the burr exit height. Similarly, ultrasonic amplitude and radial depth of cut were the main factors affecting burr width. These findings emphasize the critical role of specific parameters, highlighting their significant influence on burr formation during machining.