Experimental Study on Influence of Vibration Direction on Tool Wear and Surface Morphology in Ultrasonic Milling of Titanium Alloy

In this paper, two kinds of ultrasonic milling systems, the axial vibration of the tool and the horizontal vibration of the workpiece, were designed, built, and tested. Then taking TC4 titanium alloy as the research object, the ultrasonic machining system was used to carry out milling of titanium alloy, and the influence of different vibration directions on tool wear and surface morphology characteristics was obtained. The results show that the deviation between the designed vibration system and the theoretical value is small, and the test results are good. Then, the experimental analysis showed that when the same volume of titanium alloy material was removed under the two vibration modes, the tool vibration can reduce the tool wear compared with the workpiece vibration, no matter in terms of the wear amount of the rear tool face, or in terms of the bonding wear and oxidation wear. It is found that the root cause of surface micro-texture was the periodic change of cutting depth, and the application of axial vibration was more conducive to the generation of micro-texture than the horizontal vibration of workpiece.