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<p>A helical milling method with variable parameters to machine the through-hole was proposed to improve the surface quality and reduce defects at the entrance and exit of the through-hole for the TC4 titanium alloy tube. Firstly, based on the analysis of the helical milling mechanism, it was found that the amount of cut volume was different between positive cut and reverse cut. Then, the whole process of helical milling a through-hole was simulated by the finite element software, and the stress state and burr morphology around the hole were studied. Secondly, an orthogonal test and one-factor method were used to obtain the levels and patterns of influence of three main process parameters on milling axial force, hole surface roughness <i>R</i><sub>a</sub>, and burrs, and the preferred process parameter combinations of positive cut and reverse cut were determined. Finally, through the experimental verification, the results show that, in the process of helical milling of through-holes, when different machining parameters were used, the axial forces of positive cut and reverse cut were 148 N and 203 N, the surface roughness <i>R</i><sub>a</sub> was 0.604&#xa0;µm and 0.770&#xa0;µm, and the height of entrance burrs was 12.4&#xa0;µm and 9.4&#xa0;µm, respectively. This paper provides a technological solution for the variable parameter through-hole machining of the TC4 titanium alloy tubes and a reference for the radial through-hole machining of other related tubes.</p>

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Study on process of helical milling through-hole for the TC4 titanium alloy tube

  • 期刊论文

  • 发表日期：

    2025年5月19日

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  • Haiyi Li,
  • Anyuan Jiao,
  • Lu Li,
  • Qifan Bo,
  • Ningjun Pan,
  • Guojun Liu

摘要

A helical milling method with variable parameters to machine the through-hole was proposed to improve the surface quality and reduce defects at the entrance and exit of the through-hole for the TC4 titanium alloy tube. Firstly, based on the analysis of the helical milling mechanism, it was found that the amount of cut volume was different between positive cut and reverse cut. Then, the whole process of helical milling a through-hole was simulated by the finite element software, and the stress state and burr morphology around the hole were studied. Secondly, an orthogonal test and one-factor method were used to obtain the levels and patterns of influence of three main process parameters on milling axial force, hole surface roughness Ra, and burrs, and the preferred process parameter combinations of positive cut and reverse cut were determined. Finally, through the experimental verification, the results show that, in the process of helical milling of through-holes, when different machining parameters were used, the axial forces of positive cut and reverse cut were 148 N and 203 N, the surface roughness Ra was 0.604 µm and 0.770 µm, and the height of entrance burrs was 12.4 µm and 9.4 µm, respectively. This paper provides a technological solution for the variable parameter through-hole machining of the TC4 titanium alloy tubes and a reference for the radial through-hole machining of other related tubes.