IJAT Vol.10 No.4 pp. 647-653
doi: 10.20965/ijat.2016.p0647


Ultra-Low-Frequency Vibration Assisted Machining of Ti-6Al-4V Alloy

Tatsuya Sugihara and Toshiyuki Enomoto

Osaka University
2-1 Yamada-oka, Suita, Osaka 565-0871, Japan

Corresponding author,

February 1, 2016
May 19, 2016
July 5, 2016
cutting process, vibration assisted machining, tribology

As titanium alloys such as Ti-6Al-4V provide several benefits, including high-temperature strength and high corrosion resistance, the demand for such materials has rapidly increased, particularly in the aircraft industries. On the other hand, they are known to be among the most difficult-to-cut materials due to their mechanical and chemical properties, which make tool life extremely short. In order to solve this problem, this paper proposes a new cutting method employing ultra-low-frequency (ULF) vibration. ULF vibration ranges from less than 1 Hz to approximately 10 Hz and is generated by using a numerically-controlled machine tool axis and an NC program. The results of turning experiments showed that the developed method significantly reduces crater wear in the machining of Ti-6Al-4V, even under dry machining conditions. Moreover, the mechanism that ULF vibration affects and the effect of actual cutting time and non-cutting time in each individual vibration period on the amount of crater wear were investigated. As a result, it was found that the developed process is a promising method for achieving high performance dry machining of titanium alloys.

Cite this article as:
T. Sugihara and T. Enomoto, “Ultra-Low-Frequency Vibration Assisted Machining of Ti-6Al-4V Alloy,” Int. J. Automation Technol., Vol.10, No.4, pp. 647-653, 2016.
Data files:
  1. [1] E. O. Ezugwu, J. Bonney, and Y. Yamane, “An overview of the machinability of aeroengine alloys,” J. Mater. Process. Technol., Vol.134, pp. 233-253, 2003.
  2. [2] A. Krämer, D. Lung, and F. Klocke, “High performance cutting of aircraft and turbine components,” AIP Conf. Proc., Vol.1431, No.425, pp. 425-432, 2012.
  3. [3] A. Pramanik, “Problems and solutions in machining of titanium alloys,” Int. J. Adv. Manuf. Technol., Vol.70, No.5, pp. 919-928, 2014.
  4. [4] Z. Y. Wang and K. P. Rajurkar, “Cryogenic machining of hard-to-cut materials,” Wear, Vol.239, pp. 168-175, 2000.
  5. [5] S. Y Hong, I. Markus, and W. Jeong, “New cooling approach and tool life improvement in cryogenic machining of titanium alloy Ti-6Al-4V,” Int. J. Mach. Tools Manuf., Vol.41, pp. 2245-2260, 2001.
  6. [6] L. N. López de Lacalle, J. Pérez-Bilbatua, J. A. Sánchez, J. I. Llorente, A. Gutiérrez, and J. Albóniga, “Using High Pressure Coolant in the Drilling and Turning of Low Machinability Alloys,” Int. J. Adv. Manuf. Technol., Vol.16, No.2, pp. 85-91, 2000.
  7. [7] E. O. Ezugwu, R. B. Da Silva, J. Bonney, and Á. R. Machado, “Evaluation of the performance of CBN tools when turning Ti–6Al–4V alloy with high pressure coolant supplies,” Int. J. Mach. Tools Manuf., Vol.45, No.9, pp. 1009-1014, 2005.
  8. [8] F. Klocke and G. Eisenblätter, “Dry cutting,” CIRP Annals, Vol.46, No.2, pp. 519-526, 1997.
  9. [9] P. S. Sreejith and B. K. A. Ngoi, “Dry machining: Machining of the future,” J. Mater. Process. Technol., Vol.101, No.1-3, pp. 287-291, 2003.
  10. [10] D. E. Brehl and T. A. Dow, “Review of vibration-assisted machining,” Prec. Eng., Vol.32, pp. 153-172, 2008.
  11. [11] B. Lauwers, F. Klocke, A. Klink, A. E. Tekkaya, R. Neugebauer, and D. Mcintosh, “Hybrid processes in manufacturing,” CIRP Annals, Vol.63, No.2, pp. 561-583, 2014.
  12. [12] J. B. Mann, Y. Guo, C. Saldana, W. D. Compton, and S. Chandrasekar, “Enhancing material removal processes using modulation-assisted machining,” Tribol. Int., Vol.44, No.10, pp. 1225-1235.
  13. [13] T. Moriwaki and E. Shamoto, “Ultraprecision Diamond Turning of Stainless Steel by Applying Ultrasonic Vibration,” CIRP Annals, Vol.40, No.1, pp. 559-562, 1991.
  14. [14] E. Shamoto and T. Moriwaki, “Ultaprecision Diamond Cutting of Hardened Steel by Applying Elliptical Vibration Cutting,” CIRP Annals, Vol.48, No.1, pp. 441-444, 1999.
  15. [15] M. Yoshimaru, H. Koresawa, H, Narahara, and H. Suzuki, “Processing Micro Reactor by Non-Rotational Cutting Tool with Ultrasonic Vibration,” Int. J. Autom. Technol., Vol.3, No.5, pp. 602-609, 2009.
  16. [16] E. Shamoto and T. Moriwaki, “Study on Eliptical Vibration Cutting,” CIRP Annals, Vol.43, No.1, pp. 35-38, 1994.
  17. [17] S. Amini, E. Shamoto, N. Suzuki, and M. J. Nategh, “FE Analysis of One-Directional and Elliptical Vibration Cutting Processes,” Int. J. Autom. Technol., Vol.4, No.3, pp. 252-258, 2010.
  18. [18] Y. Wang and E. Shamoto, “Elliptical Vibration Cutting of Hardened Steel with Large Nose Radius Single Crystal Diamond Tool,” Int. J. Autom. Technol., Vol.8, No.6, pp. 820-826, 2014.
  19. [19] A. Schubert, A. Nestler, S. Pinternagel, and H. Zeidler, “Influence of ultrasonic vibration assistance on the surface integrity in turning of the aluminum alloy AA2017,” Materialwissenschaft und Werkstofftechnik, Vol.42, No.7, pp. 658-665, 2011.
  20. [20] Y. Guo, J. B. Mann, H. Yeung, and S. Chandrasekar, “Enhancing Tool Life in High-Speed Machining of Compacted Graphite Iron (CGI) Using Controlled Modulation,” Tribol. Lett, Vol.47, No.1, pp. 103-111, 2012.
  21. [21] K. Okamura, H. Sasahara, T. Segawa, and M. Tsusumi, “Low-frequency Vibration Drilling of Titanium Alloy,” JSME Int. J. Ser. C, Vol.49, pp. 76-82, 2006.
  22. [22] S. Smith, B. Woody, W. Barkman, and D. Turshy, “Temperature control and machine dynamics in chip breaking using toolpaths,” CIRP Annals, Vol.58, No.1, pp. 97-100, 2009.
  23. [23] W. Moscoso, E. Olgun, W. D. Compton, and S. Chandrasekar, “Effect of Low-Frequency Modulation on Lubrication of Chip-Tool Interface in Machining,” Trans. ASME, Vol.127, pp. 238-244, 2005.
  24. [24] D. Jianxin, L. Yousheng, and S. Wenlong, “Diffusion wear in dry cutting of Ti-6Al-4V with WC/Co carbide tools,” Wear, Vol.265, No.11-12, pp. 1776-1783, 2008.
  25. [25] H. Sasahara, G. Jin, M. Jin, and M. Murakawa, “Effect of Vibration and Atmosphere in Vibration Cutting Process (On 50 Hz Vibration Cutting),” Trans. Jpn. Soc. Mech. Eng. Ser. C, Vol.70, No.694, pp. 1843-1848, 2005.

*This site is desgined based on HTML5 and CSS3 for modern browsers, e.g. Chrome, Firefox, Safari, Edge, IE9,10,11, Opera.

Last updated on Aug. 21, 2019