Study on high-speed vibration cutting of titanium alloy considering cutting edge radii

Ultrasonic vibration cutting (UVC) is an advanced machining method used to improve machining performance and surface quality in the manufacturing industry. However, the separation characteristic disappears when the cutting speed exceeds the maximum vibration speed, which limits its wide application in high-speed machining. Therefore, this study used the finite element method (FEM) to study the high-speed vibration cutting (HVC) processing performance of titanium alloys. High-speed vibration cutting is a precision machining method with a smaller cutting depth and feed rate, so it is necessary to consider the influence of the cutting edge radii on the cutting process. The cutting edge radii on high-speed vibration cutting and the impact of the traditional cutting process are discussed. The results show that the change in the minimum uncut chip thickness caused by changing the cutting edge radii during precision cutting has a significant influence on the experimental results. In addition, a simulation model was established, and comprehensive numerical analysis and comparison of high-speed vibration cutting, ultrasonic vibration cutting, and conventional cutting (CC) were performed to tool wear, cutting temperature, cutting force, and stress distribution. The simulation results indicate that the tool wear depth of traditional cutting during high-speed cutting is up to three times that of high-speed vibration cutting. High-speed vibration cutting weakens the influence of the cutting edge radii, but this new vibration cutting method did not significantly reduce the cutting temperature under dry cutting conditions.