Surface quality investigation in high-speed dry milling of Ti-6Al-4V by using 2D ultrasonic-vibration-assisted milling platform

Ultrasonic-vibration-assisted milling (UVAM) is an advanced method for the efficient and precise machining of difficult-to-machine materials in modern manufacturing. However, the milling efficiency is limited because the ultrasonic vibration toolholder ER16 collet has a critical cutting speed. Thus, a 2D UVAM platform is built to ensure precision machining efficiency and improve the surface quality without changing the milling toolholder. To evaluate this 2D UVAM platform, ultrasonic-vibration-assisted high-speed dry milling (UVAHSDM) is performed to process a titanium alloy (Ti-6Al-4V) on the platform, and the milling temperature, surface roughness, and residual stresses are selected as the important indicators for performance analysis. The results show that the intermittent cutting mechanism of UVAHSDM combined with the specific spindle speed, feed speed, and vibration amplitude can reduce the milling temperature and improve the texture of the machined surface. Compared with conventional milling, UVAHSDM reduces surface roughness and peak-groove surface profile values and extends the range of residual surface compressive stresses from −413.96 MPa to −600.18 MPa. The excellent processing performance demonstrates the feasibility and validity of applying this 2D UVAM platform for investigating surface quality achieved under UVAHSDM.