Effect of ultrasonic vibration-assisted face milling on the surface microstructure and tribological properties

The surface with a certain microstructure and morphology has a better wear resistance and allows reduction in the drag and noise. In this work, we supplemented an ultrasonic vibration and thereby proposed the underlying mechanism in the formation of the surface microstructure of ultrasonic vibration face milling using the kinematics model. Furthermore, we established the theoretical model of the machined surface microstructure. The cutting test of TC4 titanium alloy was conducted. The rationality of the theoretical model verified by adjusting the corresponding cutting parameters and the ultrasonic parameters. In addition, the friction and wear tests of the machined surface were also performed. The results showed that the amplitude had a significant influence on the micro-morphology, roughness, and friction coefficient of the ultrasonic vibration-assisted face milling. With the increase in the amplitude, the surface roughness and friction coefficient showed an initial decreasing trend with a subsequent increase. The surface roughness declined with the increase in the cutting speed, while had little effect on the surface friction coefficient of the material.