切削参数与纵扭比耦合作用对TC4超声振动辅助钻削的影响OA

Objectives:With the rapid development of the manufacturing industry,ultrasonic equipment has continuously made technological advancements in high-speed cutting,high vibration frequencies,and large amplitudes.However,several bottleneck issues still remain.In this context,finite element simulation methods are employed to investigate the influence of cutting parameters and the coupling effect of the longitudinal-torsional ratio on drilling outcomes in practical longitudinal torsional ultrasonic vibration-assisted drilling processes,which are difficult to verify experimentally.The aim is to provide a theoretical basis and guidance for the optimization and application of the technology.Methods:This study utilizes CuttingSim software for finite element modeling of the drilling process of TC4,and the explicit solver in ABAQUS software for computation.The effects of different longitudinal torsional ratios on axial force,torque,frictional dissipation energy,and chip morphology are analyzed within a specified range of feed rate and spindle speed.Results:Under the cutting conditions set in this study,a comprehensive analysis of axial force,torque,frictional dissipation energy,and the morphology of chips generated during drilling reveals that the longitudinal amplitude significantly affects axial force and torque,while the effect of torsional amplitude is relatively small.Particularly,when the spindle speed is 6 000 r/min or below,an appropriate longitudinal torsional ratio can effectively reduce axial force and torque,which is related to the modulation effect of vibration on cutting forces.However,as spindle speed increases,especially beyond 12 000 r/min,the influence of the longitudinal torsional ratio on axial force and torque gradually diminishes.This suggests that the ultrasonic vibration-assisted drilling effect under the coupling of cutting parameters and longitudinal torsional ratio is constrained by the critical speed,beyond which the modulation effect of the longitudinal torsional ratio weakens,leading to a reduction in the advantages of ultrasonic vibration-assisted drilling.This phenomenon reflects the complex dynamic characteristics of the cutting process and highlights the need to further optimize the coordination of vibration and cutting parameters for optimal performance under high-speed cutting,high vibration frequencies,and large amplitudes.Additionally,when the longitudinal torsional ratio λ=1.25,the frictional dissipation energy reaches its minimum value of approximately 35 000 mJ,which is a 12.5%reduction compared to 40 000 mJ at λ=1.This indicates that an appropriate longitudinal-torsional ratio can effectively reduce frictional losses and optimizes energy efficiency in the cutting process.The study identifies that controlling the longitudinal-torsional ratio within 0.6 to 1.67 and keeping the spindle speed below 6 000 r/min can effectively reduce axial force and torque while improving energy efficiency during cutting.Specifically,when the spindle speed is 3 000 r/min,coupling with an appropriate longitudinal-torsional ratio and amplitude can significantly improve drilling performance.For example,at λ=1,with A1=A2=25 μm,compared to A1=A2=5 μm,axial force is reduced by 45.86%,and torque by 62.14%.When λ=1.25,with A1=25 μm and A2=20 μm,this condition not only effectively reduces axial force and torque but also decreases frictional dissipation energy by 12.5%.At λ=0.8,with A1=20 μm and A2=25 μm,a smaller chip width and the lowest average stress around the drilled hole surface are achieved,ensuring smooth chip removal while reducing stress concentration,thereby improving machining quality.Conclusions:The proposed simulation processing parameters,as part of the exploration of frontier technologies,reveal the influence of cutting parameters and the coupling effect of the longitudinal torsional ratio on TC4 ultrasonic vibration-assisted drilling.The findings provide a theoretical basis for optimizing this technology and offer valuable references for its future application and development,with significant guiding implications.