Precise machinability improvement of Ti-10V-2Fe-3Al hole using high-speed ultrasonic vibration grinding

Ti-10V-2Fe-3Al has become increasingly significant in the aerospace industry due to excellent mechanical service properties. Among its applications, hole structures are particularly significant, requiring extremely high machining precision. However, due to the poor thermal conductivity of titanium alloys, burns are prone to occur during high-speed grinding, which deteriorates machining quality and leads to tool failure. Ultrasonic machining can reduce cutting force and cutting heat through intermittent cutting, thereby improving surface quality and tool wear. In this study, a high-speed ultrasonic vibration helical hole grinding method was proposed, which realized the separation of the cutting edge from the workpiece under certain parameter conditions and enhanced the grindability of titanium alloys. Firstly, the theoretical model for ultrasonic vibration helical hole grinding was established, deriving the separation conditions and machining parameter requirements. By comparing the experimental results of helical grindings by using conventional grinding (CG) and ultrasonic grinding (UG), it was verified that UG could reduce surface roughness and extend tool life. The tool wear and its effects on the machined surface were analyzed. Finally, the influence of different spindle speeds and ultrasonic amplitudes on machining quality was investigated. The results indicated that UG extended tool life by 97% and reduced surface roughness by 62% under optimal conditions, demonstrating significant improvements in the grinding of Ti-10V-2Fe-3Al.