An innovative multi-energy field-assisted high performance machining technology: ice ultrasonic cutting for hollow thin-walled shaft of titanium alloy

Titanium alloy hollow thin-walled shafts are difficult to machine due to low rigidity, high cutting temperatures, and deformation susceptibility. To overcome these challenges, this paper proposes an innovative multi-energy field-assisted machining technique, termed ice ultrasonic cutting (IUC), aimed at improving machining accuracy and surface quality. This method integrates the structural reinforcement and phase-change cooling of ice support, the force-balancing effect of dual-tool cutting, and the intermittent cutting mechanism of ultrasonic vibration. A systematic investigation was conducted to evaluate its impact on machining performance. Experiments show IUC method significantly reduces cutting temperature and diameter error, while achieving excellent surface quality, plastic deformation layer thickness, and surface microhardness. Mechanistic analysis reveals that ice support suppresses thermal deformation and enhances rigidity from within the workpiece, whereas ultrasonic vibration promotes heat dissipation and enables precision cutting at the interface. Their synergy achieves multifield control over mechanical, thermal, and microstructural aspects, leading to a remarkable improvement in the machining accuracy and surface integrity of thin-walled shafts. This work provides a novel pathway for the high-performance manufacturing of titanium alloy hollow thin-walled shaft.