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The International Journal of Advanced Manufacturing Technology

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30-08-2022 | ORIGINAL ARTICLE

Ultrasonic and electrical discharge–assisted milling of the Ti-6Al-4 V alloy

Authors: Moran Xu, Changping Li, Rendi Kurniawan, Chen Jielin, Ye In Kwak, Saood Ali, Min Ki Choo, Tae Jo Ko

Published in: The International Journal of Advanced Manufacturing Technology | Issue 3-4/2022

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Abstract

The ultrasonic and electrical discharge–assisted milling (US-EDAM) is a new machining method designed for machining difficult-to-cut materials. It combines two machining technologies: electrical discharge machining (EDM) and conventional milling with ultrasonic vibration. The EDM in the proposed method is used to soften the surface of the material to be machined and thereby reduce the cutting force. In the meanwhile, the ultrasonic vibration of the proposed method is used to improve the discharge efficiency of the EDM and reduce the cutting force. Likewise, the milling in the present method is used to remove the workpiece’s EDM-softened surface accurately and quickly. The effects of different machining methods (including the conventional milling (CM), the ultrasonic-assisted machining (USM), the electrical discharge–assisted machining (EDAM), and the US-EDAM) on the machined material’s surface topography, plastic deformation, microscopic appearance, surface microhardness, and residual stress on the surface were compared for different machining parameters. The results confirmed that the EDM in the US-EDAM softened the surface of the material to be removed and reduced the cutting force. Furthermore, the ultrasonic vibration assistance in the US-EDAM reduced the cutting force with intermittent cutting. Notably, the surface integrity of the machined workpiece under the US-EDAM was better than the ones under the other machining methods. Hence, the US-EDAM demonstrated its capability as a new hybrid machining combining EDM, ultrasonic vibration assistance, and milling.

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Title: Ultrasonic and electrical discharge–assisted milling of the Ti-6Al-4 V alloy
Authors: Moran Xu
Changping Li
Rendi Kurniawan
Chen Jielin
Ye In Kwak
Saood Ali
Min Ki Choo
Tae Jo Ko
Publication date: 30-08-2022
Publisher: Springer London
Published in: The International Journal of Advanced Manufacturing Technology / Issue 3-4/2022
Print ISSN: 0268-3768
Electronic ISSN: 1433-3015
DOI: https://doi.org/10.1007/s00170-022-10010-y

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