Hybrid ultrasonic vibration and magnetic field assisted diamond cutting of titanium alloys

Abstract

Ultrasonic assisted machining is commonly used for machining of difficult to cut materials especially for titanium alloys in ultra-precision machining (UPM). However, the tool movements in ultrasonic assisted machining unavoidably induce surface damages and side burrs on the machined surface, in which the problem remains unsolved. To address this issue, in this study, a magnetic field is introduced in ultrasonic assisted diamond cutting in order to minimize the surface damages induced by the ultrasonic tool, and consequently improve surface finishing of machined titanium alloys. In the experiments, ultrasonic assisted diamond cutting of titanium alloys was conducted in the presence of a magnetic field. The experimental results showed that the degree of material swelling intensified by the ultrasonic tool movements was significantly reduced and suppressed in the presence of magnetic field. The area of cutting scars induced by the cyclic movements of the ultrasonic tool was minimized by the influence of the magnetic field. Moreover, the error percentages of groove depth and width generated in the presence of a magnetic field were considerably reduced to 1.69 % and 1.77 % respectively. By superimposing a magnetic field into the ultrasonic assisted diamond cutting process, the drawbacks of ultrasonic vibration assistance, especially the formation of aggregated swollen materials and cutting scars, are minimized.