Tool wear mechanisms in axial ultrasonic vibration assisted milling in-situ TiB2/7050Al metal matrix composites

The in-situ TiB2 particle reinforced aluminum matrix composites are materials that are difficult to machine,owing to hard ceramic particles in the matrix.In the milling process,the polycrystalline diamond(PCD)tools are used for machining these materials instead of carbide cutting tools,which significantly increase the machining cost.In this study,ultrasonic vibration method was applied for milling in-situ TiB2/7050A1 metal matrix composites using a TiAIN coated carbide end milling tool.To completely understand the tool wear mechanism in ultrasonic-vibration assisted milling(UAM),the relative motion of the cutting tool and interaction of workpiecetool-chip contact interface was analyzed in detail.Additionally,a comparative experimental study with and without ultrasonic vibration was carried out to investigate the infuences of ultrasonic vibration and cutting parameters on the cutting force,tool life and tool wear mechanism.The results show that the motion of the cutting tool relative to the chip changes periodically in the helical direction and the separation of tool and chip occurs in the transverse direction in one vibration period,in ultrasonic vibration assisted cutting.I arge instantaneous acceleration can be obtained in axial ultrasonic vibration milling.The cutting force in axial direction is significantly reduced by 42%-57%,40%--57%and 44%-54%,at different cutting speeds,feed rates and cutting depths,respectively,compared with that in conventional milling.Additionally,the tool life is prolonged approximately 2--5 times when the ultrasonic vibration method is applied.The tool wear pattern microcracks are only found in UAM.These might be of great importance for future research in order to understand the cutting mechanisms in UAM of in-situ TiB2/7050A1 metal matrix composites.

Model reconstruction for worn blades based on hybrid surface registrations

Model reconstruction is crucial in blade repair because it directly determines the shape precision and finish of a repaired surface.However,owing to insufficient surface data pertaining to defective regions and the unique deformation caused by harsh environments,modeling a worn blade remains difficult.Hence,a model reconstruction method for worn blades is developed in this study.Unlike conventional methods of constructing and interpolating sectional curves,the proposed method focuses on modifying a nominal computer aided design(CAD)model to reconstruct the worn blade.Through weighted rigid registration and constraint-based non-rigid registration,the design surface extracted from the nominal CAD model can be deformed to align with the surface data of the worn blade without a significant loss of its initial shape.Verification results show that the deformed design surface exhibits sufficient smoothness and accuracy for guiding tool path generation in the subsequent blade repair.

Research on ultrasonic-assisted drilling in micro-hole machining of the DD6 superalloy

The DD6 nickel-based superalloy exhibits remarkably high temperature properties;therefore,it is employed as a crucial structural material in the aviation industry.Nevertheless,this material is difficult to process.Ultrasonic-assisted drilling(UAD)combines the characteristics of vibration processing technology and conventional drilling technology,significantly improving the machinability of difficult-to-machine materials.Thus,UAD experiments were performed on micro-hole machining of DD6 superalloy in this study.The effects of amplitude,frequency,spindle speed,and feed rate on thrust force,machining quality,and drill bit wear were studied;thereafter,a comparison was drawn between these effects and those of conventional drilling(CD).The experimental results reveal that the thrust force decreases with an increase in spindle speed or a decrease in feed rate for both UAD and CD.UAD can significantly reduce the thrust force.With the same processing parameters,the greater the amplitude,the greater the reduction of the thrust force.The surface roughness of the hole wall produced by UAD is lower than that of CD.Compared with CD,UAD reduces the burr height,improves machining accuracy,and reduces drill bit wear.

Thrust force model for ultrasonic-assisted micro drilling of DD6 superalloy

As a typical refractory material,the DD6 nickelbased single-crystal superalloy has important applications in the aviation industry.Ultrasonic-assisted drilling is an advanced machining method that significantly improves machining of refractory materials.The drilling thrust force influences the hole surface quality,burr height,and bit wear.Therefore,it is necessary to predict the thrust force during ultrasonic-assisted drilling.However,there are few reports on the modeling of the thrust force in the ultrasonicassisted drilling of micro-holes.A thrust force prediction model for ultrasonic-assisted micro-drilling is proposed in this study.Based on the basic cutting principle,the dynamic cutting speed,dynamic cutting thickness,and acoustic softening effect caused by ultrasonic vibrations are factored into this model.Through model calibration,the specific friction force and specific normal force coefficients were determined.The model was verified through ultrasonic-assisted drilling experiments conducted at different feed rates,spindle speeds,frequencies,and amplitudes.The maximum and minimum errors of the average thrust force were 10.5%and 2.3%,respectively.This model accurately predicts the thrust force based on the parameters used for ultrasonic-assisted micro-hole drilling and can assist in the analysis and modeling of DD6 superalloy processing.