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Axial ultrasonic vibration-assisted cutting (AUVC) has been proved to have better machining performance compared with conventional cutting methods; however, the effect of numerous and complex influencing factors on machining performance has not been clearly revealed, and a recommended combination of cutting conditions has not been proposed yet, especially for difficult-to-machine material such as Ti6Al4V alloy. This paper focuses on the experimental and theoretical investigation into Ti6Al4V machining performance with AUVC method. First, a retrospective of the separation characteristics of AUVC is provided, and the variable parameter cutting characteristics are demonstrated. The influencing factors on machining performance are classified into four categories: machining parameters, vibration parameters, tool choice, and cooling conditions. The relationship between these factors in terms of their effect on machining performance is established theoretically. Then, it describes experiments to determine the influence of these factors on cutting force, tool life, and surface roughness. For absolute influence, the orders for cutting force, tool life, and surface roughness are respectively cutting depth > amplitude > feed rate > rotation speed, rotation speed > feed rate > amplitude > cutting depth, and feed rate > amplitude > cutting depth > rotation speed. However, for relative influence, the order is unified as amplitude > feed rate > rotation speed > cutting depth. Finally, it suggests a smaller feed rate, larger amplitude, moderate rotation speed, and smaller cutting depth in addition to a WC tool coated with TiAlN and used under HPC cooling condition for optimal performance of AUVC. This recommendation is based on the theoretical analysis and experimental results of cutting force, surface roughness, and tool life. [ABSTRACT FROM AUTHOR]

As a relatively new grinding technology, ELID (electrolytic in-process dressing) is widely used in some businesses. The oxide layer plays an important role in ELID grinding performance. The purpose of this work is to investigate the state of the oxide layer on ELID grinding wheel surfaces based on workpiece-cathode and tool-cathode. The thickness and surface topography of the oxide layer were measured from ELID grinding experiments based on workpiece-cathode and tool-cathode in different controlled dressing current. The normal grinding force was also compared in ELID grinding with workpiece-cathode and tool-cathode. According to the results, there are some caves on the surface of the oxide layer in ELID grinding with workpiece-cathode. With increasing controlled dressing current, the surface of the oxide layer becomes discontinuous in ELID grinding with workpiece-cathode. And the surface of the oxide layer becomes smoother with increasing controlled dressing current in ELID grinding with tool-cathode. Meanwhile, it was found that the oxide layer in ELID grinding with workpiece-cathode is thicker than that in ELID grinding with tool-cathode. Moreover, the normal grinding force in ELID grinding with workpiece-cathode is smaller than that in ELID grinding with tool-cathode. The results are helpful to improve the ELID grinding performance and apply ELID grinding technology with workpiece-cathode to abroad industrial applications. [ABSTRACT FROM AUTHOR]