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<p>Ti-6Al-4&#xa0;V titanium alloy thin-walled parts are susceptible to fatigue and plastic deformation due to the distribution of machining residual stresses. To reasonably regulate the distribution of residual stress inside the workpiece, this study investigates the influence of freezing temperature, tool coating, tool path, processing temperature, and feed speed on the distribution of residual stress in Ti-6Al-4&#xa0;V titanium alloy thin-walled parts by combining an ice-covered milling experiment with low-temperature cutting simulation. The results indicate that ice-covered milling significantly enhances residual compressive stress by a range of 46% to 57.14%, with maximum improvement observed at a processing temperature of −15&#xa0;°C. The AlTiN tool coating, with low friction and hardness, significantly improves the residual compressive stress of titanium alloy thin-walled parts, reaching −483.3&#xa0;MPa. Compared with annular feeding, lateral and longitudinal feeding can increase the residual compressive stress value by 18.87 and 23.22%, respectively. The error between simulation and experiment can be minimized to 1.69%. Decreasing processing temperature increases residual compressive stress on the workpiece surface. Increasing the feed rate initially increases and then decreases residual tensile stress on the surface. The low-temperature two-dimensional cutting finite element model accurately predicts residual stress distribution in ice-covered milling and provides an effective practical scheme for thin-walled parts with high quality and precision. </p>

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Investigation of Residual Stress in Ice-Covered Milling of Ti-6Al-4V Alloy Thin-Walled Parts with Experimental and Finite Element Simulations

  • 期刊论文

  • 发表日期：

    2025年6月30日

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  • Yongquan Jin,
  • Xiaoqiang Wu,
  • Feng Gao,
  • Taiyan Gong,
  • Xiaofan Deng,
  • Rui Xue

摘要

Ti-6Al-4 V titanium alloy thin-walled parts are susceptible to fatigue and plastic deformation due to the distribution of machining residual stresses. To reasonably regulate the distribution of residual stress inside the workpiece, this study investigates the influence of freezing temperature, tool coating, tool path, processing temperature, and feed speed on the distribution of residual stress in Ti-6Al-4 V titanium alloy thin-walled parts by combining an ice-covered milling experiment with low-temperature cutting simulation. The results indicate that ice-covered milling significantly enhances residual compressive stress by a range of 46% to 57.14%, with maximum improvement observed at a processing temperature of −15 °C. The AlTiN tool coating, with low friction and hardness, significantly improves the residual compressive stress of titanium alloy thin-walled parts, reaching −483.3 MPa. Compared with annular feeding, lateral and longitudinal feeding can increase the residual compressive stress value by 18.87 and 23.22%, respectively. The error between simulation and experiment can be minimized to 1.69%. Decreasing processing temperature increases residual compressive stress on the workpiece surface. Increasing the feed rate initially increases and then decreases residual tensile stress on the surface. The low-temperature two-dimensional cutting finite element model accurately predicts residual stress distribution in ice-covered milling and provides an effective practical scheme for thin-walled parts with high quality and precision.