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Research Papers

Experiments and Finite Element Simulation of Ultrasonic Assisted Drilling

[+] Author and Article Information
Hossein Paktinat

Department of Manufacturing,
Faculty of Mechanical Engineering,
University of Kashan,
Kashan 8731753153, Iran

Saeid Amini

Department of Manufacturing,
Faculty of Mechanical Engineering,
University of Kashan,
Kashan 8731753153, Iran
e-mail: amini.s@kashanu.ac.ir

1Corresponding author.

Manuscript received November 20, 2017; final manuscript received May 12, 2018; published online July 9, 2018. Assoc. Editor: Zhijian J. Pei.

J. Manuf. Sci. Eng 140(10), 101002 (Jul 09, 2018) (10 pages) Paper No: MANU-17-1563; doi: 10.1115/1.4040321 History: Received November 20, 2017; Revised May 12, 2018

In this study, ultrasonic assisted drilling (UAD) is performed to investigate the effect of ultrasonic vibrations on common difficulties existed in conventional drilling (CD). UAD is a promising and advanced technique by which a harmonic movement with high frequency and low amplitude is superimposed on the movement of work material or cutting tool. The study is conducted both experimentally and numerically; at first, a UAD system is designed, manufactured, and carried out on a milling machine and then experimental tests are accomplished. In the following, experimental results are supported by the help of three-dimensional (3D) finite element simulation. Finally, the dependent parameters such as the burr height and cylindricity of the ultrasonically and conventionally drilled workpiece are measured and compared. Briefly, it was proved that the intermittent movement of drill bit in the direction of feed rate results in broken and discontinuous chips by which built-up-edge (BUE) is reduced and hole quality is improved. In addition, the burr height, which is known as unwanted projection of material at the exit surface of pieces, can notably decrease, if UAD is considered.

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References

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Figures

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Fig. 1

Longitudinal mode shape of horn and tool at frequency of 20,117 Hz (above), a real picture of assembled horn and drill tool (below)

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Fig. 2

The whole vibratory tool

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Fig. 3

Experimental setup for UAD

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Fig. 4

Three-dimensional chip simulation of drilling process

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Fig. 5

Simulation of UAD process

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Fig. 6

Comparison of burr size in UAD and CD processes, feed rate 100 mm/min and cutting speed 1000 rpm

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Fig. 7

The mean value of thrust force in both UAD and CD processes, cutting speed 1000 rpm and feed rate 100 mm/min

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Fig. 8

Comparison of burr size in UAD and CD processes, feed rate 200 mm/min and cutting speed 1000 rpm

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Fig. 9

Comparison of chip formation and type in CD and UAD, cutting speed 1000 rpm and feed rate 200 mm/min

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Fig. 10

Comparing of formed chip in CD and UAD, cutting speed 1000 rpm and feed rate 100 mm/min

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Fig. 11

Temperature distribution of CD and UAD at drilling step 10,000, cutting speed 1000 rpm and feed rate 150 mm/min

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Fig. 12

Drilled hole circularity versus feed rate at cutting speed of 1500 rpm

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Fig. 13

Drilled hole surface roughness (Ra) versus feed rate at cutting speed 1000 rpm

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Fig. 14

Drill skidding at cutting speed of 1000 rpm and feed rate of 200 mm/min

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