Experimental and numerical study of ultrasonically-assisted drilling

Area of Science:

• Manufacturing Engineering
• Materials Science

Background:

• Conventional drilling faces challenges like built-up edge formation and poor chip morphology.
• Ultrasonic vibration is explored as a method to mitigate these drilling issues.

Purpose of the Study:

• To analyze the impact of ultrasonic vibrations on drilling difficulties using 3D finite element simulation.
• To experimentally evaluate the influence of harmonic drill bit movement on built-up edge formation.
• To investigate heat generation on tool faces during ultrasonically-assisted drilling.

Main Methods:

• 3D finite element simulation of ultrasonically-assisted drilling.
• Experimental evaluation of built-up edge formation under harmonic drill bit movement.
• Analysis of heat generation on tool faces via simulation.

Main Results:

• Ultrasonic vibration reduces heat transfer time between the drill bit and workpiece, leading to less built-up edge formation.
• The intermittent motion of the drill bit in the vibration method results in lower built-up edge formation compared to conventional drilling.
• Linear motion in the feed direction increases chip strain and damage, producing broken chips.

Conclusions:

• Ultrasonically-assisted drilling effectively reduces built-up edge formation.
• The vibration-induced chip strain in this method leads to improved chip breaking.
• This technique offers a viable solution for enhancing conventional drilling processes.