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<p>The titanium alloy of Ti6Al4V belongs to difficult-to-machine material, and how to effectively improve its cutting performance to meet the application requirements is still a challenge. As a new composite processing method, the laser-ultrasonic-vibration assisted machining (LUVM) has a great potential in improving the cutting performance of Ti6Al4V. In order to explore the dynamic machining process and cutting mechanism of Ti6Al4V, a finite element method (FEM) model was established for the LUVM, and the chip morphology, cutting force, temperature and stress under two chip states were studied. The results show that the flat-top rectangular spot is more suitable for the laser preheating compared with the Gaussian circular spot. The thermal softening effect of laser preheating and the periodic intermittent cutting state of ultrasonic vibration have important effects on the curvature radius of chip, segmentation degree, cutting force, cutting temperature, and stress state during the LUVM process. Compared with conventional turning (CT), laser assisted machining (LAM) and ultrasonic vibration assisted machining (UVM), the LUVM can significantly reduce the cutting force under both continuous and serrated chip states, and there is a certain quantitative relationship between cutting force and reduction rate among the four processing methods. The results also further prove that the LUVM has a greater advantage in improving the cutting performance of Ti6Al4V compared with LAM and UVM.</p>

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Cutting mechanism of laser-ultrasonic-vibration assisted machining of Ti6Al4V under two chip states based on FEM model

  • 期刊论文

  • 发表日期：

    2025年2月27日

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  • Qianwei Jiang,
  • Yang Hua,
  • Xianfu Liu,
  • Li Li,
  • Jianhua Zhang,
  • Fazhan Li,
  • Jinguo Han,
  • Zhengkai Li

摘要

The titanium alloy of Ti6Al4V belongs to difficult-to-machine material, and how to effectively improve its cutting performance to meet the application requirements is still a challenge. As a new composite processing method, the laser-ultrasonic-vibration assisted machining (LUVM) has a great potential in improving the cutting performance of Ti6Al4V. In order to explore the dynamic machining process and cutting mechanism of Ti6Al4V, a finite element method (FEM) model was established for the LUVM, and the chip morphology, cutting force, temperature and stress under two chip states were studied. The results show that the flat-top rectangular spot is more suitable for the laser preheating compared with the Gaussian circular spot. The thermal softening effect of laser preheating and the periodic intermittent cutting state of ultrasonic vibration have important effects on the curvature radius of chip, segmentation degree, cutting force, cutting temperature, and stress state during the LUVM process. Compared with conventional turning (CT), laser assisted machining (LAM) and ultrasonic vibration assisted machining (UVM), the LUVM can significantly reduce the cutting force under both continuous and serrated chip states, and there is a certain quantitative relationship between cutting force and reduction rate among the four processing methods. The results also further prove that the LUVM has a greater advantage in improving the cutting performance of Ti6Al4V compared with LAM and UVM.