Cutting performance and surface quality of Ti-6Al-4V by longitudinal ultrasonic vibration-assisted high-speed dry milling with coated carbide tools

Longitudinal ultrasonic vibration-assisted high-speed dry milling (LUVAHSDM) is adopted to improve the cutting performance and surface quality of Ti-6Al-4V (TC4). Multifaceted comparisons are presented in terms of milling force, milling temperature, tool wear, 3D surface roughness, and residual stress, utilizing AlCrN, AlCrSiN, AlTiN, and AlTiSiN-coated tools. The results show that the maximum milling forces in the feed and longitudinal directions both decreased at first and then increased with the increasing of Al element contents, during which the single edge and average flank wear increased. Therefore, the surface roughness of TC4 becomes more uniform using AlTiN-coated tools, and the residual stress is significantly reduced to 98.57 MPa. Combining the results of milling force, milling temperature, tool wear, 3D surface roughness and residual stress data, it is found that AITiN-coated tools achieve excellent cutting performance and surface quality. The excellent machining performance of coated carbide tools demonstrates the feasibility and effectiveness of applying LUVAHSDM methods.