Simulation and experimental study of ultrasonic vibration-assisted milling of GH4169 high- temperature alloy

GH4169 high-temperature alloy is widely used in aerospace and other fields because of its excellent fatigue, radiation, oxidation, and corrosion resistance. However, milling forces, high temperatures, and machining hardening can occur during milling processing. To explore the machining characteristics of GH4169 high-temperature alloy, an ultrasonic vibration-assisted milling model was established to study the effect of ultrasonic milling parameters on the milling pro-cess. The simulation results show that: the increase of ultrasonic amplitude can effectively reduce the machining stress, improve the chip-breaking effect and reduce the milling force; with the rise of milling speed, the separation characteristic is weakened, which is not conducive to chip breaking; the increase of radial cutting width will increase the machining stress and improve the milling force. Finally, by comparing the actual machining and simulation results, the error is within 10%, which verifies the feasibility of the simulation study and provides guidance for ultrasonic milling of GH4169 high-temperature alloy.(c) 2023 THE AUTHORS. Published by Elsevier BV on behalf of Faculty of Engineering, Alexandria University. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/ licenses/by-nc-nd/4.0/).