Optimization Design and Experimental Study of High-Frequency Milling Force Measurement Platform Based on Ultrasonic Vibration

Ultrasonic vibration-assisted milling (UVAM) is widely used in aerospace precision component processing due to its high efficiency and low cutting force characteristics. However, high-frequency vibration (>16 kHz) induces dynamic response hysteresis and noise interference in force measurement platforms, limiting the accuracy of milling force measurement. This study proposes a hybrid structural optimization method (Hybrid TO-GA) that integrates topology optimization and genetic algorithms. A nonlinear dynamic model is established by incorporating the Stribeck friction model and Bouc-Wen hysteresis effects. The optimized platform achieves a 34.7% increase in first-order natural frequency (9.5→12.8 kHz) and a 22% reduction in mass. Experimental results demonstrate that under 20 kHz operating conditions, the measurement error decreases to 4.3% (compared to 11.5% for traditional platforms), and the signal-to-noise ratio (SNR) improves to 46 dB. The optimized platform extends the tool life of TC4 titanium alloy by 23% and enhances machining efficiency by 18%. This research provides a high-precision and lightweight solution for high-frequency milling force measurement.