Finite Element Simulation Analysis of Axial Ultrasonic Vibration Assisted Cutting of Titanium Alloy TC4

In ABAQUS simulations, the Young's modulus and Poisson's ratio are set to vary with temperature by assigning fixed values. This approach can impact the reliability and accuracy of the simulation results. In this paper, the temperature-dependent functions of Young's modulus and Poisson's ratio are incorporated into ABAQUS using its secondary development capabilities. And simulate the ultrasonic vibration-assisted cutting (UVAC) process of titanium alloy TC4. Based on the analysis of the simulation results, the fitting function operates within the temperature range of the cutting simulation, which is of guiding significance for further development. It is discovered that as the amplitude increases, the chips gradually transition from C-shaped to irregular blocky ones, the cutting force gradually decreases, while the influence depth of the residual compressive stress first reduces and then increases, and when the amplitude is 16 microns, the influence depth of the residual compressive stress is the minimum, being 0.05 mm. In comparison to amplitude, the frequency has a relatively small impact on the chip shape and cutting force. As the frequency rises, the influence depth of the residual compressive stress shows a downward trend. With the increase of the feed rate, the chip width and crimp radius of the ultrasonic vibration-assisted cutting become wider, while the cutting force and residual stress gradually increase.