Simulation of the influence of ultrasonic parameters on the cutting forces of ultrasonic vibration assisted cutting of titanium alloy

Ultrasonic vibration-assisted cutting, as an advanced composite machining technology, has garnered increasing attention in the processing of challenging materials in recent years. Titanium alloy, renowned for its exceptional properties, including high strength, high-temperature resistance, and robust corrosion resistance, stands out as a crucial structural material. To explore the impact of ultrasonic vibration parameters on cutting forces in the ultrasonic vibration-assisted cutting of titanium alloy, finite element simulation analysis was employed. Employing the amplitude in the direction of the main cutting force and the ultrasonic vibration frequency as variables, we analyzed the variations in the main cutting force and feed force under different ultrasonic vibration parameters. The finite element simulation results reveal that, with an increase in the amplitude in the direction of the main cutting force, the main cutting force gradually increases. However, with an increase in the amplitude in the direction of the feed force, both the main cutting force and feed force exhibit a gradual increase. Furthermore, as the ultrasonic vibration frequency rises, both the main cutting force and feed force gradually decrease. Finite element simulation shows increasing main cutting force amplitude reduces main cutting force, while higher frequency decreases both forces. High-frequency and low-amplitude parameters are preferred to reduce cutting force and tool wear rate.