Insights into the synergistic effect of multi-energy fields for Ti-6Al-4 V under laser-ultrasonic vibration assisted milling
摘要
Energy field assisted machining has gained widespread attention as an efficient and high-quality processing methods. It is critical to clarify the various deformation behaviors of material under different energy fields. This study investigates the synergistic effect of laser-ultrasonic multi-energy field on the cutting deformation of Ti-6Al-4 V. Experiments were conducted with constant ultrasonic milling parameters while varying the laser power from 0 to 300 W. Analysis of segmented cutting force signals provided insights into the dual-field mechanism. Compared with conventional milling, ultrasonic milling reduced the average forces by 10% in Fx, 9% in Fy, and 2% in Fz. With the introduction of laser energy field, an effective power range of 200–250 W was identified. At 250 W, Fx and Fz decreased to 6.31 N and 4.06 N, respectively. The corresponding resultant force dropped by 21%. Chip micromorphology indicated that 200 W was the optimal laser power for Ti-6Al-4 V removal in the chosen range, producing uniform and defect-free chips. The corresponding surface roughness Ra reached a minimum value of 0.307 μm. Comparative analyses of various surface morphologies and hardnesses revealed that appropriate laser-ultrasonic parameters promote material removal while maintaining surface hardness (343 HV0.2 at 200 W). The laser-ultrasonic vibration assisted milling method demonstrates significant potential for improving the machining performance and surface quality of difficult-to-machine materials.
Graphical abstract