Finite Element Simulation Of Elliptical Ultrasonic Vibration Cutting Of Titanium Alloy

As an important material in the field of aviation and aerospace,titanium alloy has become more and more popular in aerospace structural parts.However,due to its low thermal conductivity,small deformation coefficient,large cutting force,high cutting temperature,high chemical activity,small elastic modulus,and easy to produce serrated chip,the machinability of titanium alloy is poor,and it is a typical difficult to cut material.The ultrasonic vibration cutting technology is a machining method that a periodic reciprocating motion with the high frequency is applied on the cutting tool,which belongs to the intermittent cutting,can reduce the cutting force,cutting temperature and tool wear effectively.However,with the development of computer and finite element method,the research of ultrasonic vibration cutting of titanium alloy has become a hot issue in the field of cutting of titanium alloy because of expensive equipment,low efficiency and difficult to obtain result parameters.In this paper,in order to solve the problem of finite element simulation in elliptical ultrasonic vibration cutting of titanium alloy,the elliptical ultrasonic vibration cutting of titanium alloy was carried out by using AdvantEdge FEM finite element software.The main research contents of this paper are as follows:(1)The research status of the ultrasonic vibration cutting of titanium alloy is analyzed.Ultrasonic vibration cutting technology can improve the cutting performance of titanium alloys effectively in theoretical analysis,such as reducing cutting force and cutting temperature,producing burrs hardly,extending tool life and so on.(2)The finite element model of two dimensional elliptical ultrasonic vibration cutting of titanium alloy is established based on metal cutting theory,thermal elastic-plastic finite element method,ultrasonic cutting theory and AdvantEdge FEM finite element software.The modeling process is described in detail,including the establishment of geometric model,meshing,the constitutive model of titanium alloy,tool-chip friction model,adaptive meshing and the setting of ultrasonic vibration parameters.(3)The influence of machining parameters on the cutting force and temperature of elliptical ultrasonic vibration of titanium alloy is studied through finite element simulation.Compared with the conventional machining of the corresponding cutting parameters,the influence of the cutting speed,feed rate and the cutting depth on the cutting force and the cutting temperature are studied by the single-variable method.A one dimensional ultrasonic vibration finite element model was established and compared with the experimental results of other researchers.(4)The influence of machining parameters on the residual stress of elliptical ultrasonic vibration of titanium alloy is studied through finite element simulation.Compared with the conventional machining of the corresponding cutting parameters,the influence of the cutting speed and cutting depth on the residual stress are studied by the single-variable method.(5)On the basis of(3)and(4),the influence of elliptical ultrasonic vibration parameters(vibration frequency,horizontal vibration amplitude and vertical vibration amplitude)on cutting is studied.For a set of cutting parameters,the influence of elliptical ultrasonic vibration frequency and amplitude on the cutting force,cutting temperature and residual stress are studied by the single-variable method.