Longitudinal torsional ultrasonic vibrations with different longitudinal torsional ratios were introduced into the extrusion tapping process to explore the effects of ultrasonic vibrations in different vibration directions on extrusion tapping of small blind holes in Ti-6Al-4V. First, the motion trajectory model of longitudinal torsional ultrasonic vibration extrusion tapping (LT-UVET) was established, and the intermittent extrusion separation characteristics of edge teeth during the LT-UVET process were analyzed. In addition, finite element simulation was used to analyze the stress and torque of the LT-UVET process with different . The simulation results show that the effective stress and torque of LT-UVET at different are reduced compared with conventional extrusion tapping (CET). When the ultrasonic vibration direction coincided with the thread direction ( = 0.08), the effective stress and torque were the lowest. A tapping experiment platform was built and two ultrasonic tools with different aspect ratios were used to conduct tapping experiments. Experimental results show that the torque of LT-UVET is significantly lower than that of CET. Among them, when = 0.08, the effect on torque reduction is more obvious. In addition, LT-UVET can also promote metal flow forming, reduce material accumulation, and improve thread surface integrity.
Rodríguez RipollMTomalaAMTotolinV, et al. Performance of nanolubricants containing MoS2 nanotubes during form tapping of zinc-coated automotive components. J Manuf Process2019; 39: 167–180.
2.
BrandãoGLde SilvaPMDCFreitasSA, et al. State of the art on internal thread manufacturing: a review. Int J Adv Manuf Technol2020; 110(11–12): 3445–3465.
3.
EzugwuEOWangZM.Titanium alloys and their machinability—a review. J Mater Process Technol1997; 68(3): 262–274.
4.
HouYJZuoDWSunYL, et al. Semi-analytical torque modeling of Ti-6al-4V-alloy internal trapezoidal thread extrusion forming with an emphasis on low-frequency torsional vibration. J Mater Process Technol2020; 286: 116812.
5.
ZiskinMC.Fundamental physics of ultrasound and its propagation in tissue. Radiographics1993; 13(3): 705–709.
6.
WuCChenSChengK, et al. Investigation of strengthening effect on the machining rigidity in longitudinal torsional ultrasonic milling of thin-plate structures. Proc IMechE, Part B: J Engineering Manufacture2020; 234(3): 665–670.
7.
GamidiKKrishna PasamV.Performance evaluation of spot cooled vibration assisted turning for Ti6Al4V alloy. Proc IMechE, Part B: J Engineering Manufacture2024; 238(1–2): 235–248.
8.
QiuYYinJCaoY, et al. Generation mechanism modeling of surface topography in tangential ultrasonic vibration-assisted grinding with green silicon carbide abrasive wheel. Proc IMechE, Part B: J Engineering Manufacture2022; 236(6–7): 694–706.
9.
WangJFengPZhangJ.Investigations on the edge-chipping reduction in rotary ultrasonic machining using a conical drill. Proc IMechE, Part B: J Engineering Manufacture2016; 230(7): 1254–1263.
10.
SoniaPJainJKSaxenaKK.Influence of ultrasonic vibration assistance in manufacturing processes: a review. Mater Manuf Process2021; 36(13): 1451–1475.
11.
ZhangDYChenDC.Relief-face friction in vibration tapping. Int J Mech Sci1998; 40(12): 1209–1222.
12.
KuoKL.Experimental investigation of ultrasonic vibration-assisted tapping. J Mater Process Technol2007; 192–193: 306–311.
13.
ZhangBYangFWangJ.Fundamental aspects in vibration-assisted tapping. J Mater Process Technol2003; 132(1–3): 345–352.
14.
PawarSJoshiSS.Experimental analysis of axial and torsional vibrations assisted tapping of titanium alloy. J Manuf Process2016; 22: 7–20.
15.
NathCRahmanMAndrewSSK. A study on ultrasonic vibration cutting of low alloy steel. J Mater Process Technol2007; 192: 159–165.
16.
YaoZKimGYFaidleyL, et al. Acoustic softening and hardening of aluminum in high-frequency vibration-assisted micro/meso forming. Mater Manuf Process2013; 28(5): 584–588.
17.
YaoZKimGYFaidleyL, et al. Effects of superimposed high-frequency vibration on deformation of aluminum in micro/meso-scale upsetting. J Mater Process Technol2012; 212(3): 640–646.
18.
TeideltEStarcevicJPopovVL.Influence of ultrasonic oscillation on static and sliding friction. Tribol Lett2012; 48(1): 51–62.
19.
PetruzelkaJSarmanovaJSarmanA.The effect of ultrasound on tube drawing. J Mater Process Technol1996; 60(1-4): 661–668.
20.
GuoZNLeeTCYueTM, et al. Study on the machining mechanism of WEDM with ultrasonic vibration of the wire. J Mater Process Technol1997; 69(1–3): 212–221.
21.
LiYChengZChenX, et al. Constitutive modeling and deformation analysis for the ultrasonic-assisted incremental forming process. T Int J Adv Manuf Tech2019; 104(5–8): 2287–2299.
22.
RasoliMAAbdullahAFarzinM, et al. Influence of ultrasonic vibrations on tube spinning process. J Mater Process Technol2012; 212(6): 1443–1452.
23.
BaiYYangM.Optimization of metal foils surface finishing using vibration-assisted micro-forging. J Mater Process Technol2014; 214(1): 21–28.
24.
KirchnerHOKKrompWKPrinzFB, et al. Plastic deformation under simultaneous cyclic and unidirectional loading at low and ultrasonic frequencies. Mater Sci Eng1985; 68(2): 197–206.
25.
RoznerAG.Effect of ultrasonic vibration on coefficient of friction during strip drawing. J Acoust Soc Am1971; 49(5A): 1368–1371.
26.
UrbakhMKlafterJGourdonD, et al. The nonlinear nature of friction. Nature2004; 430(6999): 525–528.
27.
AminiSHosseinpour GolloAPaktinatH.An investigation of conventional and ultrasonic-assisted incremental forming of annealed AA1050 sheet. Int J Adv Manuf Tech2017; 90(5-8): 1569–1578.
28.
VahdatiMMahdavinejadRAminiS.Investigation of the ultrasonic vibration effect in incremental sheet metal forming process. Proc IMechE, Part B: J Engineering Manufacture2017; 231(6): 971–982.
29.
WarringtonCKapoorSDeVorR.Experimental investigation of thread formation in form tapping. J Manuf Sci Eng2005; 127(4): 829–836.
30.
WarringtonCKapoorSDeVorR.Finite element modeling for tap design improvement in form tapping. J Manuf Sci Eng2005; 128(1): 65–73.
31.
JaspersSPFCDautzenbergJH. Material behaviour in conditions similar to metal cutting: flow stress in the primary shear zone. J Mater Process Technol2002; 122(2–3): 322–330.
