Experimental Study On Ultrasonic Vibration Assisted Milling Of Aluminum Alloy

With excellent corrosion resistance, electrical conductivity, thermal conductivity,and low density and cost efficiency, aluminum alloy has been used as a main material of thin-walled parts. But the viscosity and plasticity of aluminum alloy is so large that the processing deformation and vibration will be easily caused by the cutting forces and heat during the milling of thin-walled parts, which influences the processing quality and precision. Ultrasonic vibration assisted milling can effectively reduce the cutting force, cutting temperature and improve the machining precision and the surface quality of workpiece. Therefore, in this paper, ultrasonic vibration is brought into the milling process of 6063-T5 aluminum alloy thin-walled parts, then discusses the feasibility in ultrasonic vibration assisted milling 6063-T5 aluminum alloy processing thin-walled parts. The main contents of this paper are as follows:(1) The experimental platform of ultrasonic vibration assisted milling 6063-T5 aluminum alloy thin-walled parts is designed and set up, then vibration characteristic test of ultrasonic device is finished. And the average milling force model of ultrasonic vibration assisted milling of aluminum alloy is established, and its results show that:ultrasonic vibration assisted milling can reduce the milling force.(2) This paper studies the forces variation characteristics of the ordinary milling and ultrasonic vibration assisted milling of 6063-T5 aluminum alloy thin-walled parts under different milling parameters. And the result shows as follows: the ultrasonic vibration milling can reduce the cutting force in a certain range, which decreases with the increase of spindle speed and amplitude of ultrasonic vibration, and increases with the increase of feed per tooth and milling depth.(3) This paper studies the processing amplitude variation characteristics of the ordinary milling and ultrasonic vibration assisted milling of 6063-T5 aluminum alloy thin-walled parts under different milling parameters. And the result shows as follows:the ultrasonic vibration milling can reduce cutting vibration in a certain range, which enhances the stability of the system. And it can reduce processing amplitude byincreasing the spindle speed, amplitude of ultrasonic vibration, milling depth or decreasing the feed per tooth; but more feed per tooth and milling depth will result in greater processing amplitude.(4) This paper studies the surface quality of the ordinary milling and ultrasonic vibration assisted milling 6063-T5 aluminum alloy thin-walled parts. And the result shows as follows: the ultrasonic milling can reduce the milling forces and processing amplitude, which reduce the gap of actual wall thickness and theoretical wall thickness, then reduce the processing deformation, improve the surface quality of the workpiece, the efficiency of chips removal.