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Increasing demands on component properties are leading to the development of high-performance materials for which conventional production methods are reaching their limits from an economic and ecological point of view. In recent years, two technologies have been developed that show great potential compared to conventional machining processes, parti...
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... by using a milling process in climb milling. Entry into the workpiece was performed by rolling into the cut, which leads to a reduction in vibration and tool wear when milling difficult-to-machine materials [23]. Afterwards, the workpiece material was removed under constant contact conditions. A schematic of the milling process is shown in Fig. ...
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Titanium alloys are crucial in precision manufacturing due to their exceptional properties, but traditional machining methods lead to tool wear, deformation, and high costs. Conventional cooling fluids reduce heat but cause environmental issues, necessitating more sustainable solutions. Cryogenic Minimum Quantity Lubrication (CMQL) technology, usin...
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The cutting forces, residual stresses, and workpiece distortion in machining processes largely influence the quality of the end product. An advanced technique for the amelioration of these parameters is ultrasonic-assisted milling (UAM), which induces high-frequency vibrations onto the cutting tool to intermittently disrupt tool-workpiece contact, aiding in the removal of material more effectively. This study focuses on ultrasonic-assisted milling and its effects on cutting forces, workpiece distortion, tensile residual stress, and surface integrity via finite element simulation and experimental approaches. A numerical model was built in ABAQUS first and validated against experimental observations. In the experiments, aluminum 7075 was selected as the workpiece material, and various machining parameters including spindle speed, feed rate, and milling method were investigated. The results indicated that UAM reduced cutting forces up to 25%, workpiece distortion of 21.5%, and tensile residual stresses by 23% compared to conventional milling (CM). Microscopic investigations revealed better surface integrity in the UAM compared to CM, as trace scratches were less and there were fewer surface defects. The comparison between simulations and experimental findings also yielded good correlation with a deviation in output parameters within 11%. This finding demonstrates that ultrasonic-assisted milling is an effective method for improving dimensional accuracy and surface quality in the machining process.
This chapter offers an insightful examination of the advancements in machining aerospace materials, focusing on ultrasonic vibration-assisted (UVA) machining and minimum quantity lubrication (MQL) techniques. It begins with an introduction to the unique challenges associated with machining these advanced materials and how UVA machining and MQL have emerged as innovative solutions to address these challenges. The chapter then systematically explores the effects of these techniques on various aspects of the machining process. It discusses how UVA machining and MQL influence cutting forces, leading to potential reductions in tool wear and energy consumption. The impact on surface quality is also examined, highlighting improvements in terms of both physical appearance and structural integrity. The chapter further discusses the changes in chip morphologies that result from employing UVA machining and MQL, which are crucial for understanding the material removal mechanisms and overall machining efficiency. Finally, it addresses the implications of these techniques on tool wear, emphasizing their potential to extend tool life and maintain machining accuracy. This chapter not only synthesizes current research but also provides practical insights for industry professionals seeking to optimize machining processes for aerospace materials.
