Comparison of Thrust Force in Ultrasonic Assisted Drilling and Conventional Drilling of Aluminum Alloy

Abstract

The origin of drilling force in drilling with twist drill is quite complicated owning to the complex shape of the drill bit cutting edges. In this paper, the drilling experiments both with and without the ultrasonic were designed and conducted on aluminum alloy with pre-drilled hole. The drilling force was tested and the different effects between the cutting edges of the twist drill on the drilling force were analyzed under various drilling parameters including the spindle speed, feed rate and vibration amplitude. The drilling force of conventional drilling (CD) and ultrasonic assisted drilling (UAD) was characterized and the roles of the ultrasonic vibration in drilling were discussed.

Kinematic analysis and process stability of ultrasonic-assisted drilling

“…Considering aluminium alloys, the level of force reduction is similar. Li et al [35] obtained a reduction of approx. 28% (EN AW-7075) and Paktitat and Amini [36] of approx.…”

Characterization of Thrust Force, Temperature, Chip Morphology and Power in Ultrasonic-assisted Drilling of Aluminium 6061

“…They provided illustrations that show the effect of vibration on chip size compared to CD; however, the authors have not discussed the setup they used to apply ultrasonic vibrations to the drilling process. Li et al (2016) used a 30-kHz UAD system to study the effect of machining parameters on thrust force of the cutting lips and chisel edge in CD and UAD, separately. They pre-drilled pilot holes in a 12-mm thick aluminum 7075 to eliminate the thrust force of the chisel edge and their results showed the feed rate would affect thrust force of the chisel edge more than the thrust force of the cutting lips.…”

Effects of Cantilever Length and Diameter of the Cutting Tool on Resonance Frequency in Ultrasonic Assisted Machining

“…Ultrasonic assisted machining (UAM) is a technique in which vibrations with smallamplitude, high-frequency are superimposed to the relative motion between cutting tool and workpiece during the machining operation in order to achieve better cutting performance [1]. For example, abundant advantages of ultrasonic assisted drilling have been found as to provide significant reduction of thrust force [2]- [6], improvements in built-up edge [2], [7], burr size [2], [8], reduction of drilling torque [9], improving the chip evacuation [10]- [13]. In the application of ultrasonic assisted machining, the design of the vibratory unit for clamping the cutting tool is a critical issue.…”