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<p>At presented work, based on longitudinal torsional ultrasonic-assisted milling (LTUAM) kinematics analysis and element method, an analytical model of LTUAM milling force considering instantaneous undeformed cutting thickness and blunt edge radius was established, to study the effects of tool wear and milling parameters on cutting force during LTUAM of heat-resistant cast steel. The model combines the stress evolution of the flank face and shear plane, and the accuracy is confirmed by a single factor test. The results indicate that there is a 10% margin of error between the experimental and analytical results. Within the range of milling parameters, milling force Fx and Fy decrease by 55.64% and 63.92%, respectively, with an increase in spindle speed; by 30.99% and 71.84%, respectively, with an increase in feed rate per tooth; and by 38.72% and 27.89%, respectively, with an increase in radial cutting depth. The milling force is minimized when the ultrasonic amplitude is 1.5&#xa0;μm, resulting in a reduction of 34.95% and 31.47% in the milling force Fx and Fy when compared to the ordinary milling. The application of ultrasonic vibration was able to suppress the increase in tool wear rate and reduce the milling force within a certain range.</p>

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Effect of the tool wear on milling forces in longitudinal torsional ultrasonic-assisted milling of heat-resistant cast steel

  • 期刊论文

  • 发表日期：

    2025年2月21日

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  • Pan Wei,
  • Ying Niu,
  • Shaofan Gu,
  • Jingjing Niu

摘要

At presented work, based on longitudinal torsional ultrasonic-assisted milling (LTUAM) kinematics analysis and element method, an analytical model of LTUAM milling force considering instantaneous undeformed cutting thickness and blunt edge radius was established, to study the effects of tool wear and milling parameters on cutting force during LTUAM of heat-resistant cast steel. The model combines the stress evolution of the flank face and shear plane, and the accuracy is confirmed by a single factor test. The results indicate that there is a 10% margin of error between the experimental and analytical results. Within the range of milling parameters, milling force Fx and Fy decrease by 55.64% and 63.92%, respectively, with an increase in spindle speed; by 30.99% and 71.84%, respectively, with an increase in feed rate per tooth; and by 38.72% and 27.89%, respectively, with an increase in radial cutting depth. The milling force is minimized when the ultrasonic amplitude is 1.5 μm, resulting in a reduction of 34.95% and 31.47% in the milling force Fx and Fy when compared to the ordinary milling. The application of ultrasonic vibration was able to suppress the increase in tool wear rate and reduce the milling force within a certain range.