Design and surface analysis in large-amplitude longitudinal ultrasonic vibration-assisted milling of TC4 titanium alloy under dry conditions.

Exploring advanced green processing technology is the way to achieve efficient precision manufacturing of difficult-to-machine materials and carbon-neutral development. Thus, the design and manufacture of a large-amplitude longitudinal ultrasonic vibration-assisted milling (LALUVAM) toolholder is conducted in this work. For validation of the developed toolholder a TC4 titanium alloy milling experiment is carried out. Multifaceted analysis are presented in terms of milling force, surface roughness, and residual stress. The results indicate that the LALUVAM toolholder exhibits excellent performance in milling TC4 materials. What's more, the disordered tool feed trajectory is eliminated when using the LALUVAM toolholder in milling TC4. Moreover, resultant forces F is reduced 36.61%. The minimum surface roughness and a smaller range of compressive residual stress can be obtained under LALUVAM condition. Meanwhile, a scaled texture can be generated on the surface of TC4 by using harmonic movement of end mill. In the future, LALUVAM toolholder will be able to meet the 10 μm to 20 μm ultrasonic machining and provide better results in terms of reduced milling forces and surface roughness. [ABSTRACT FROM AUTHOR]