Chatter stability and precision during high-speed ultrasonic vibration cutting of a thin-walled titanium cylinder

• 作者: Zhenlong PENG Deyuan ZHANG Xiangyu ZHANG
• 来源期刊: 中国航空学报（英文版）
• 年，卷（期）: 2020,（12）
• 所属期刊栏目: Material Engineering and Mechanical Manufacturing
• 页码范围: 3535-3549
• 页数: 15页
• 语种: 英文

摘要

Titanium alloys are widely used in the aviation and aerospace industries due to their unique mechanical and physical properties. Specifically, thin-walled titanium (Ti) cylinders have received increasing attention for their applications as rocket engine casings, aircraft landing gear, and aero-engine hollow shaft due to their observed improvement in the thrust-to-weight ratio. However, the conventional cutting (CC) process is not appropriate for thin-walled Ti cylinders due to its low thermal conductivity, high strength, and low stiffness. Instead, high-speed ultrasonic vibration cutting (HUVC) assisted processing has recently proved highly effective for Ti-alloy machining. In this study, HUVC technology is employed to perform external turning of a thin-walled Ti cylinder, which represents a new application of HUVC. First, the kinematics, tool path, and dynamic cutting thickness of HUVC are evaluated. Second, the phenomenon of mode-coupling chatter is analyzed to determine the effects and mechanism of HUVC by establishing a critical cut-ting thickness model. HUVC can increase the critical cutting thickness and effectively reduce the average cutting force, thus reducing the energy intake of the system. Finally, comparison experi-ments are conducted between HUVC and CC processes. The results indicate that the diameter error rate is 10％or less for HUVC and 51％for the CC method due to a 40％reduction in the cutting force. In addition, higher machining precision and better surface roughness are achieved during thin-walled Ti cylinder manufacturing using HUVC.