目的 针对二维超声辅助车削对增材制造钛合金加工性能和作用机理研究,提高增材制造钛合金表面质量、降低切削力和减少刀具磨损。方法 在干车削与湿车削环境下,通过传统车削与二维超声振动车削性能对比研究,分析不同条件下切削力、表面粗糙度、表面硬度和刀具表面切屑黏结的差异性。结果 在干切环境下,与传统车削相比,二维超声振动车削对主切削力的降低幅度最大可达25.50%。在湿切环境下,二维超声振动车削主切削力比传统车削主切削力降低幅度最高可达22.73%。二维超声振动车削比传统车削在干切环境下表面粗糙度降低幅度为21.28%~37.11%,而在湿切环境下表面粗糙度降幅为14.68%~38.63%。二维超声振动车削增材制造钛合金硬度测量平均值均高于传统车削。增材制造钛合金在二维超声振动车削时刀具前刀面黏结物比传统车削前刀面黏结物更少。结论 在相同车削参数下,与传统车削相比,二维超声振动车削能够更好地降低主切削力、表面粗糙度,同时也有效地提高工件表面硬度和抗黏结性能。
Abstract
Additive manufacturing of titanium alloys is widely used in aerospace, medical, and high-end equipment due to its high design freedom, high material utilization, and excellent mechanical properties. However, due to issues such as insufficient surface quality and accuracy, further machining is required. Studies have shown that two-dimensional ultrasonic vibration turning can effectively improve the surface roughness, surface hardness, and tool life of machined materials. The work aims to conduct turning experiments on titanium alloys additively manufactured with two-dimensional ultrasonic vibration- assisted turning technology under different feed rates and machining environments, followed by a comprehensive analysis of cutting force, surface roughness, surface hardness, and tool adhesion. The cutting forces under different machining conditions were measured by a Kistler 9257B dynamometer. Surface morphology under different feed rates was observed with a Super Viewer surface profiler to compare conventional turning and two-dimensional ultrasonic vibration turning (Fig.4), and then surface roughness was measured (Fig.5 and Fig.6). In addition, based on different dry and wet environments, surface hardness under different feed rates in conventional and two-dimensional ultrasonic vibration-assisted machining was measured with a digital micro-Vickers hardness tester TMVS-1 (Fig.7), and the reasons for higher surface hardness under ultrasonic vibration in different environments were analyzed. Tool surface adhesion and EDX composition of adhered materials under different machining methods were analyzed (Fig.8), and the effects of two-dimensional ultrasonic vibration turning on tool adhesion were discussed. Under dry cutting conditions, compared to conventional turning, two-dimensional ultrasonic vibration turning could reduce the main cutting force by up to 25.50% at a feed rate of 0.05 mm/r. Under wet cutting conditions, the main cutting force in two-dimensional ultrasonic vibration turning could decrease by as much as 22.73% compared to conventional turning. However, when the feed rate increased to 0.15 mm/r, the difference in main cutting force between two-dimensional ultrasonic vibration turning and conventional turning was minimal for both dry and wet cutting, and this gap further narrowed with the increasing feed rate. The surface textures of workpieces processed by conventional turning and two-dimensional ultrasonic vibration turning showed clear differences. The surface after conventional turning exhibited a "ploughing" texture, while the surface after two-dimensional ultrasonic vibration turning showed a "fish scale" pattern. Two-dimensional ultrasonic vibration turning reduced surface roughness by 21.28% to 37.11% under dry cutting, and by 14.68% to 38.63% under wet cutting, compared with conventional turning. The average hardness of additively manufactured titanium alloys was higher in two-dimensional ultrasonic vibration turning than in conventional turning, because two-dimensional ultrasonic vibration effectively reduced cutting temperature, mitigating high-temperature softening. Due to ultrasonic vibration, adhesion on the tool's rake face was less during two-dimensional ultrasonic vibration turning than during conventional turning. Under wet cutting conditions, tool surface adhesion was lower than under dry cutting for both methods. Under the same turning parameters, compared with conventional turning, two-dimensional ultrasonic vibration turning better reduces the main cutting force and surface roughness, while providing higher workpiece surface hardness and improved anti-adhesion performance on the tool surface.
关键词
增材制造钛合金 /
超声振动 /
切削质量 /
切削机理 /
刀具黏结
Key words
additively manufactured titanium alloy /
ultrasonic vibration /
cutting quality /
cutting mechanism /
tool adhesion
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基金
安徽省重点研究与开发计划项目（2022a05020006）; 安徽省高等学校科学研究重大项目（2022AH040134）; 汽车零部件三维设计与制造关键技术研发与应用项目（HX-2025-07-031）; 智能汽车线控底盘系统安徽省重点实验室开放课题项目（QCKJJ202503）; 安徽工程大学本科教学质量提升计划项目（2025xqhz01）
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