Influences of machining parameters on tool performance when high-speed ultrasonic vibration cutting titanium alloys

Tool performance is a key factor in evaluating machining processes. To improve machining productivity and part quality, researchers have conducted numerous studies on improving tool performance, such as tool design, coatings, functional micro textures, cooling/lubrication conditions, cutting parameter optimization, and intermittent cutting. Focusing on materials that are difficult to cut (i.e., Ti alloys), this paper explores a high-speed ultrasonic vibration cutting method that combines intermittent cutting, cooling, and lubrication. Through theoretical analysis and experiments on tool wear, cutting force, temperature, etc., the influence of machining parameters on tool performance is investigated. The results show that a large separation effect coupled with good cooling and lubrication conditions is key to improving tool performance. Among these, the feedrate and phase shift resulting from the rotary (spindle) speed are the core machining parameters. On this basis, the choice of machining parameters is summarized to provide a reference for the high-efficient machining of Ti alloys for scholars and engineers. First, cooling and lubrication conditions, such as dry machining and fluids, are determined. The duty cycle is then set from 0.5 to 0.6 via a relatively small feedrate value (i.e. 0.005 mm/r) and a π phase shift. Finally, the cutting speed and depth of cut are chosen according to the requirements of machining efficiency and cost.