Scholarlink

<p>This study investigates the effects of ultrasonic vibration amplitude and milling speed on the machining performance of 7075-T6 aluminum alloy. A three-dimensional milling model was established in ABAQUS finite element software, and single-factor simulations were conducted to analyze the influence of ultrasonic impact amplitude (UIA) and milling speed on triaxial cutting forces, residual stress, plastic strain, ultrasonic-induced micro-pits, and surface morphology. Results show that all three cutting force components increase with milling speed, with sensitivity ranked as Fy &gt; Fx &gt; Fz. At UIA = 25%, the milling force increased by approximately 3.47 N, marking a 46.44% rise. The maximum residual compressive stress occurred at UIA = 40%, reaching 170.48&#xa0;MPa-18.59&#xa0;MPa and 170.48&#xa0;MPa higher than those under UIA = 25% and UIA = 10%, respectively. When milling speed increased from 30&#xa0;m/min to 90&#xa0;m/min under UIA = 25%, residual compressive stress rose by 999.75&#xa0;MPa, a 172.42% increase. At UIA = 10%, the equivalent plastic strain rose by 0.139, a 33.67% growth. At a milling speed of 30&#xa0;m/min, micro-pit debris appeared as fine powder, mainly composed of carbon (47.27%) and oxygen (33.43%), with trace elements accounting for 6.44%. At 75&#xa0;m/min and 90&#xa0;m/min, pitting corrosion was observed, with surface compositions dominated by aluminum (Al: 83.28-84.51%), zinc (Zn: 6.39-7.01%), and carbon (C: 4.05-6.91%). These findings demonstrate that increasing ultrasonic amplitude and milling speed significantly affects force generation, residual stress accumulation, and surface integrity, offering insights into optimizing high-speed ultrasonic-assisted milling of aluminum alloys.</p>

错误：搜索内容不能为空，请输入英文关键词
错误：关键词超出字数限制，请精简
高级检索

Research on the Machining Mechanism of 7075-T6 Aluminum Alloy Enhanced by Ultrasonic Vibration Impact

  • 期刊论文

  • 发表日期：

    2025年9月8日

查看全文
  • Ping Zhang,
  • Shuai Ge,
  • Songting Zhang,
  • Tengfei Zhang

摘要

This study investigates the effects of ultrasonic vibration amplitude and milling speed on the machining performance of 7075-T6 aluminum alloy. A three-dimensional milling model was established in ABAQUS finite element software, and single-factor simulations were conducted to analyze the influence of ultrasonic impact amplitude (UIA) and milling speed on triaxial cutting forces, residual stress, plastic strain, ultrasonic-induced micro-pits, and surface morphology. Results show that all three cutting force components increase with milling speed, with sensitivity ranked as Fy > Fx > Fz. At UIA = 25%, the milling force increased by approximately 3.47 N, marking a 46.44% rise. The maximum residual compressive stress occurred at UIA = 40%, reaching 170.48 MPa-18.59 MPa and 170.48 MPa higher than those under UIA = 25% and UIA = 10%, respectively. When milling speed increased from 30 m/min to 90 m/min under UIA = 25%, residual compressive stress rose by 999.75 MPa, a 172.42% increase. At UIA = 10%, the equivalent plastic strain rose by 0.139, a 33.67% growth. At a milling speed of 30 m/min, micro-pit debris appeared as fine powder, mainly composed of carbon (47.27%) and oxygen (33.43%), with trace elements accounting for 6.44%. At 75 m/min and 90 m/min, pitting corrosion was observed, with surface compositions dominated by aluminum (Al: 83.28-84.51%), zinc (Zn: 6.39-7.01%), and carbon (C: 4.05-6.91%). These findings demonstrate that increasing ultrasonic amplitude and milling speed significantly affects force generation, residual stress accumulation, and surface integrity, offering insights into optimizing high-speed ultrasonic-assisted milling of aluminum alloys.