Hybrid pulsed-electric vibratory machining for improved processing of Ti-6Al-4 V alloy

We introduce a novel hybrid Pulsed-Electric Vibratory Machining process that integrates high-frequency ultrasonic vibrations with an externally applied electric field to enhance the machinability of aerospace-grade alloys, demonstrated here on Ti-6Al-4 V. Electrically-assisted (EA) manufacturing leverages the electroplastic effect, wherein the application of electric current facilitates plastic deformation by reducing flow stress and enhancing material ductility, thereby improving machinability. The novelty is the integration of electrically-assisted electroplasticity with ultrasonic vibratory turning into a single process. We investigate the influence of high and low current densities and varying current frequencies, including continuous current profiles, on the turning process, in conjunction with mechanical ultrasonic vibration. The significance is evidenced by substantial reductions in cutting force, improved surface integrity, and favourable thermal profiles. This work highlights, for the first time, the potential of EA-ultrasonic hybrid machining as an effective strategy for improving machining operations for difficult-to-machine materials.