Research on the surface morphology of titanium alloy ultrasonic elliptical vibration cutting considering flank extrusion and material rebound

To explore the influencing factors of surface topography and roughness in ultrasonic elliptical vibration cutting, this study proposed a new prediction model based on the formation mechanism of ultrasonic elliptical vibration cutting surface topography. Applying mathematical transformation ideas and discretization processing, the model considers linear velocity, rear face extrusion, and material rebound and utilizes MATLAB to carry out a simulation analysis of the surface topography. It also verifies the validity and accuracy of the model through experiments. The effects of cutting mode, velocity ratio, feed amount, and tool radius on the surface morphology of ultrasonic elliptical vibration cutting were analyzed using the proposed model. Results show that under the condition of K_m < -tanα, the rear face extrusion and material rebound will have a specific impact on the 2-D residual height. In particular, the error between the theoretical roughness of the model and the actual roughness is 20.85%, which can provide some theoretical basis for the selection of machining parameters.