Wear Behavior of Ceramic Tools in Longitudinal‐Torsional Ultrasonic Vibration‐Assisted Milling

Austenitic heat‐resistant cast steel is widely used in the manufacture of automotive exhaust manifolds and other occasions for its superior performance. Longitudinal‐torsional ultrasonic vibration‐assisted milling (LTUM) technology can effectively slow down tool wear and improve surface quality. In presented work, a longitudinal‐torsion ultrasonic milling method of heat‐resistant cast steel ceramic milling cutter is proposed, and the effects of the cutting performance and tool wear mechanisms of ordinary milling (OM) and ultrasonic longitudinal‐torsional milling of austenitic heat‐resistant cast steel with ceramic tools are investigated. The relationship between the milling force and the process parameters used are investigated, and the cutting surface quality and wear characteristics of ceramic tools are studied. The results show that compared to OM, LTUM has a lower cutting force, with an average milling force reduction of 34.65%; the surface quality of LTUM‐machined workpieces is higher, with a reduction in surface roughness of 68.98%. Ceramic tools in LTUM machining conditions than OM tool life increased by 140%. The main forms of wear of ceramic tools are spalling wear, abrasive wear, and adhesive wear.