Analytical model of workpiece temperature in axial ultrasonic vibration-assisted milling in situ TiB2/7050Al MMCs

In recent years, as a new method developed for machining difficult-to-cut materials, ultrasonic vibration-assisted machining technology has been attracting more and more attentions due to its superior properties in reducing cutting temperature. However, analytical models revealing the mechanism and predicting the cutting temperature for ultrasonic vibration-assisted machining are still needed to be developed. In this paper, an analytical model was established to predict the workpiece temperature for ultrasonic vibration-assisted milling of in situ TiB2/Al MMCs. The heat intensity would be directly determined by the cutting force which was significantly influenced by the ultrasonic vibration motion. Meanwhile, the moving heat source theory was applied for calculating dynamic heat flux and partition ratio. Besides, material properties, tool geometry, cutting parameters, and vibration parameters were taken into account for workpiece temperature modeling. Finally, the developed analytical temperature model was validated by milling experiments with and without ultrasonic vibration on in situ TiB2/7050Al metal matrix composites. The relative errors between model prediction results and experiments were smaller than 17%, indicating that the proposed model could provide workpiece temperature prediction reliably and accurately. Furthermore, the established analytical model could be used not only in ultrasonic vibration-assisted milling but also in conventional milling for the metal matrix composites.