Simulation and Experimental Study on Serrated Chip Formation in Torsional Ultrasonic Milling of Titanium Alloys

Simulation and Experimental Study on Serrated Chip Formation in Torsional Ultrasonic Milling of Titanium Alloys | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Simulation and Experimental Study on Serrated Chip Formation in Torsional Ultrasonic Milling of Titanium Alloys Mingli Zhao, Mingli Zhao, Hao Wang, Wenbin Song, Boxi Xue, Xiaobo Wang This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-6495308/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 15 Sep, 2025 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted 5 You are reading this latest preprint version Abstract The Ti-6Al-4V titanium alloy has found extensive application in aerospace engineering due to its elevated specific strength and corrosion resistance properties. Notably, the material exhibited low thermal conductivity but high chemical reactivity, which often resulted in the formation of irregular serrated chips during the processing stage. This in turn will affect the processing efficiency. Conventional chip suppression methods present challenges in regulating the chip segmentation frequency. Longitudinal torsional vibration assisted milling (LTUAM) offers a novel approach to enhancing chip morphology through high-frequency intermittent cutting. In this paper, we present a two-dimensional milling force-chip morphology coupled finite element model. This model is established by constructing a longitudinal and torsional composite ultrasonic kinematics model combined with the modified Johnson-Cook damage criterion. We then carry out relevant tests to verify the simulation. The experimental validation demonstrated that the relative errors between the simulated and measured values of F x and F y are less than 10%. Furthermore, the geometric features obtained from the simulation, such as tooth pitch and serration frequency, meet the requirements for machining accuracy. It has been determined that the ultrasonic amplitude exerts a substantial nonlinear modulation effect, leading to a 34.01% and 30.82% reduction in the main milling forces, F x and F y , respectively, when compared to the conventional process at an amplitude of 4 µm. Concurrently, The frequency of chip serration is increased by 171%. The frequency is 56 times per millimeter, and the pitch of the teeth is reduced by 28%. When the amplitude is more than 4 micrometers, the cutting force is rebounded due to the decrease in the proportion of the tool-workpiece effective separation time. The amplitude of 6 µm triggers the inertial fracture of the chip, which causes the tooth pitch to rebound. This results in a 67.5% reduction in the degree of serration compared to conventional milling. This study unveils the nonlinear regulatory mechanism of longitudinal torsional ultrasonic amplitude on the cutting process of Ti-6Al-4V, establishing a process parameter optimization system with the coupling relationship of ultrasonic amplitude-chip morphology as the core. The process is supported by a new theory and method, which makes it possible to machine titanium alloy components at both high efficiency and low damage. Longitudinal torsional vibration assisted milling Separation characteristics Serrated chip Finite element Chip geometric characteristics Full Text Cite Share Download PDF Status: Published Journal Publication published 15 Sep, 2025 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted Editorial decision: Minor Revisions Needed 02 Jun, 2025 Reviewers agreed at journal 25 Apr, 2025 Reviewers invited by journal 24 Apr, 2025 Editor assigned by journal 23 Apr, 2025 First submitted to journal 21 Apr, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-6495308","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":447544524,"identity":"dd115495-5a66-430a-b792-f73b6b0c5475","order_by":0,"name":"Mingli 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Notably, the material exhibited low thermal conductivity but high chemical reactivity, which often resulted in the formation of irregular serrated chips during the processing stage. This in turn will affect the processing efficiency. Conventional chip suppression methods present challenges in regulating the chip segmentation frequency. Longitudinal torsional vibration assisted milling (LTUAM) offers a novel approach to enhancing chip morphology through high-frequency intermittent cutting. In this paper, we present a two-dimensional milling force-chip morphology coupled finite element model. This model is established by constructing a longitudinal and torsional composite ultrasonic kinematics model combined with the modified Johnson-Cook damage criterion. We then carry out relevant tests to verify the simulation. The experimental validation demonstrated that the relative errors between the simulated and measured values of \u003cem\u003eF\u003c/em\u003e\u003csub\u003e\u003cem\u003ex\u003c/em\u003e\u003c/sub\u003e and \u003cem\u003eF\u003c/em\u003e\u003csub\u003e\u003cem\u003ey\u003c/em\u003e\u003c/sub\u003e are less than 10%. Furthermore, the geometric features obtained from the simulation, such as tooth pitch and serration frequency, meet the requirements for machining accuracy. It has been determined that the ultrasonic amplitude exerts a substantial nonlinear modulation effect, leading to a 34.01% and 30.82% reduction in the main milling forces, \u003cem\u003eF\u003c/em\u003e\u003csub\u003e\u003cem\u003ex\u003c/em\u003e\u003c/sub\u003e and \u003cem\u003eF\u003c/em\u003e\u003csub\u003e\u003cem\u003ey\u003c/em\u003e\u003c/sub\u003e, respectively, when compared to the conventional process at an amplitude of 4 \u0026micro;m. Concurrently, The frequency of chip serration is increased by 171%. The frequency is 56 times per millimeter, and the pitch of the teeth is reduced by 28%. When the amplitude is more than 4 micrometers, the cutting force is rebounded due to the decrease in the proportion of the tool-workpiece effective separation time. The amplitude of 6 \u0026micro;m triggers the inertial fracture of the chip, which causes the tooth pitch to rebound. This results in a 67.5% reduction in the degree of serration compared to conventional milling. This study unveils the nonlinear regulatory mechanism of longitudinal torsional ultrasonic amplitude on the cutting process of Ti-6Al-4V, establishing a process parameter optimization system with the coupling relationship of ultrasonic amplitude-chip morphology as the core. The process is supported by a new theory and method, which makes it possible to machine titanium alloy components at both high efficiency and low damage.\u003c/p\u003e","manuscriptTitle":"Simulation and Experimental Study on Serrated Chip Formation in Torsional Ultrasonic Milling of Titanium Alloys","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-04-28 03:31:24","doi":"10.21203/rs.3.rs-6495308/v1","editorialEvents":[{"type":"communityComments","content":0},{"type":"decision","content":"Minor Revisions Needed","date":"2025-06-02T11:05:03+00:00","index":"","fulltext":""},{"type":"reviewerAgreed","content":"","date":"2025-04-25T23:39:04+00:00","index":0,"fulltext":""},{"type":"reviewersInvited","content":"","date":"2025-04-24T14:34:54+00:00","index":"","fulltext":""},{"type":"editorAssigned","content":"","date":"2025-04-24T01:39:03+00:00","index":"","fulltext":""},{"type":"submitted","content":"The International Journal of Advanced Manufacturing Technology","date":"2025-04-21T06:46:41+00:00","index":"","fulltext":""}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false}}],"origin":"","ownerIdentity":"ccf32c2e-6ed0-48a8-ba29-1c1f2b0c3eb0","owner":[],"postedDate":"April 28th, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"published-in-journal","subjectAreas":[],"tags":[],"updatedAt":"2025-09-22T16:00:54+00:00","versionOfRecord":{"articleIdentity":"rs-6495308","link":"https://doi.org/10.1007/s00170-025-16441-7","journal":{"identity":"the-international-journal-of-advanced-manufacturing-technology","isVorOnly":false,"title":"The International Journal of Advanced Manufacturing Technology"},"publishedOn":"2025-09-15 15:56:50","publishedOnDateReadable":"September 15th, 2025"},"versionCreatedAt":"2025-04-28 03:31:24","video":"","vorDoi":"10.1007/s00170-025-16441-7","vorDoiUrl":"https://doi.org/10.1007/s00170-025-16441-7","workflowStages":[]},"version":"v1","identity":"rs-6495308","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-6495308","identity":"rs-6495308","version":["v1"]},"buildId":"8U1c8b4HqxoKbykW_rLl7","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}