Research Papers

Improving Productivity in an Ultrasonic-Assisted Drilling Vertical Machining Center

[+] Author and Article Information
M. A. Moghaddas

1250 Arthur E. Adams Drive,
Columbus, OH 43221
e-mail: amoghaddas@ewi.org

M. A. Short

1250 Arthur E. Adams Drive,
Columbus, OH 43221
e-mail: mshort@ewi.org

N. R. Wiley

1250 Arthur E. Adams Drive,
Columbus, OH 43221
e-mail: nwiley@ewi.org

A. Y. Yi

Department of Integrated Systems Engineering,
Ohio State University,
1971 Neil Avenue,
Columbus, OH 43210
e-mail: Yi.71@osu.edu

K. F. Graff

1250 Arthur E. Adams Drive,
Columbus, OH 43221
e-mail: kgraff@ewi.org

Manuscript received May 2, 2017; final manuscript received January 11, 2018; published online March 9, 2018. Assoc. Editor: Laine Mears.

J. Manuf. Sci. Eng 140(6), 061002 (Mar 09, 2018) (9 pages) Paper No: MANU-17-1300; doi: 10.1115/1.4039109 History: Received May 02, 2017; Revised January 11, 2018

Ultrasonic-assisted machining, which is the application of ultrasonic vibrations to standard or “conventional” machine tools for processes such as drilling, milling, and turning, is a rapidly developing technology aimed at increasing the productivity of machining processes. While a solid foundation is being established through laboratory-based research studies, typically these processes have not yet progressed to fulfill the demanding requirements of the factory floor. The objective of the current work is to transition the ultrasonic-assisted drilling (UAD) process from the laboratory to a production system compatible with automated machining systems. This work details the design and development of an ultrasonic drilling module that has sufficient strength, stiffness, and accuracy for production demands, while maintaining powerful levels of ultrasonic vibrations that result in lowered drilling forces and faster feed rates. In addition, this work will review prior work in UAD, including the development of a module based on a vibration-isolating case using a standard tool holder. Performance of the system is shown to provide thrust force reductions, while maintaining or improving surface finish and drilling accuracy. The results from drilling several materials are presented.

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Fig. 1

UAD module sectional view

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Fig. 2

Interference bolt connection of front mass and case

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Fig. 3

Modal analysis: (a) transducer and (b) UAD module

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Fig. 4

Experimental setup for UAD

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Fig. 5

Thrust force data from dynamometer—Aluminum 6061, N = 1296 rpm, f = 660 mm/min: (a) A = 0 and (b) A = 11 μm

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Fig. 6

Torque data from dynamometer—Aluminum 6061, N = 1296 rpm, f = 660 mm/min: (a) A = 0 and (b) A = 11 μm

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Fig. 7

Average values of thrust force and torque at (a) different amplitudes for scenario 1 and (b) different feed rates for scenario 2

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Fig. 8

Productivity improvement of UAD versus CD of aluminum 6061, Stainless Steel 316, and Titanium (Ti–6Al–4V)




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