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<p>Tungsten alloy is widely used in aerospace and military defense fields due to its high melting point, high hardness, and high wear resistance. However, traditional processing methods often cause surface defects (such as thermal damage, edge collapse, and burrs) and high cutting forces, which seriously restrict their precision machining capabilities. Therefore, this study proposes a novel Ultrasonic-Electrical Composite Milling (UECM) method. The core idea of this method is to coordinate the electroplastic effect of ultrasonic vibration and pulse current, optimize the material removal mechanism, and improve surface quality. The experiment uses W-Mo tungsten alloy as the subject, builds an experimental platform, and conducts ultrasonic-electric composite milling experiments on the W-Mo tungsten alloy. The machining performance of traditional Dry Milling (DM), Ultrasonic-Assisted Milling (UAM), Electroplastic-Assisted Milling (EPAM), and UECM is systematically compared. The results demonstrate that UECM reduces heat accumulation via the periodic tool-workpiece separation induced by ultrasonic vibration. This effect, combined with the electroplasticity from pulsed current and Joule thermal softening, significantly enhances material plasticity. The surface roughness (<i>Sa</i>) decreased from 1.8465&#xa0;μm (dry milling) to 1.262&#xa0;μm, a decrease of 31.6%, and the peak cutting force is reduced by more than 30%. The change in chip morphology from short fragments to continuous bands verifies the transformation of the machining mechanism from brittle fracture to plastic shear, further reflecting the improvement in material plasticity. Under the ultrasonic-electrical composite milling process, milling experiments with varying pulse parameters show that the surface roughness first decreases and then increases with the increase in voltage (60–120&#xa0;V). The surface roughness decreases with increasing pulse frequency, exhibiting an inverse correlation. This study provides novel insights into composite process machining and proposes an innovative method for the efficient and precise fabrication of tungsten alloys.</p>

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Research on the effect of ultrasonic-electric pulse composite milling on the machining performance of tungsten alloy

  • 期刊论文

  • 发表日期：

    2025年6月7日

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  • Xin Zhang,
  • Zhanjie Li,
  • Gang Jin,
  • Yuanhao Ma,
  • Yipu Bian,
  • Mengpan Hu,
  • Chong Li,
  • Shaokun Luo

摘要

Tungsten alloy is widely used in aerospace and military defense fields due to its high melting point, high hardness, and high wear resistance. However, traditional processing methods often cause surface defects (such as thermal damage, edge collapse, and burrs) and high cutting forces, which seriously restrict their precision machining capabilities. Therefore, this study proposes a novel Ultrasonic-Electrical Composite Milling (UECM) method. The core idea of this method is to coordinate the electroplastic effect of ultrasonic vibration and pulse current, optimize the material removal mechanism, and improve surface quality. The experiment uses W-Mo tungsten alloy as the subject, builds an experimental platform, and conducts ultrasonic-electric composite milling experiments on the W-Mo tungsten alloy. The machining performance of traditional Dry Milling (DM), Ultrasonic-Assisted Milling (UAM), Electroplastic-Assisted Milling (EPAM), and UECM is systematically compared. The results demonstrate that UECM reduces heat accumulation via the periodic tool-workpiece separation induced by ultrasonic vibration. This effect, combined with the electroplasticity from pulsed current and Joule thermal softening, significantly enhances material plasticity. The surface roughness (Sa) decreased from 1.8465 μm (dry milling) to 1.262 μm, a decrease of 31.6%, and the peak cutting force is reduced by more than 30%. The change in chip morphology from short fragments to continuous bands verifies the transformation of the machining mechanism from brittle fracture to plastic shear, further reflecting the improvement in material plasticity. Under the ultrasonic-electrical composite milling process, milling experiments with varying pulse parameters show that the surface roughness first decreases and then increases with the increase in voltage (60–120 V). The surface roughness decreases with increasing pulse frequency, exhibiting an inverse correlation. This study provides novel insights into composite process machining and proposes an innovative method for the efficient and precise fabrication of tungsten alloys.