Modeling of 3D FEM milling process with ultrasonic vibrations of Ti-6Al-4V titanium alloy and the effect of changes in frequency and amplitude of vibrations on shear force

By reducing the shear force in machining processes, benefits such as tool life and improved machined surface quality can be achieved. In recent decades, one of the most effective ways to reduce shear force is to apply ultrasonic vibrations to tools or workpieces in the machining process. In this paper, a 3D simulation of the milling process using ultrasonic vibrations on Ti-6Al-4V titanium alloy with 5 frequencies and 6 vibrational amplitudes has been performed using ABAQUS software. The simulation results show that the maximum shear force does not change with increasing frequency from 18 to 20 kHz. In this paper, different modes of milling process to achieve the minimum shear force according to the frequency and vibration amplitude parameters have been investigated and by comparing the results, it has been observed that the minimum shear force is obtained between different simulation modes for frequency 18 kHz and vibration amplitude 25 micron.