Drilling force model for forced low frequency vibration assisted drilling of Ti-6Al-4V titanium alloy

Yang, Huibin; Ding, Wenfeng; Chen, Yan; Laporte, Sylvain; Xu, Jie; Fu, Yucan

doi:10.1016/j.ijmachtools.2019.103438

Cited by 63 publications

(21 citation statements)

References 34 publications

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“…This technique is characterized by the addition of external or internal vibrational energy (either high or low frequency) to the conventional machining movement to reduce cutting forces and generate thinner chip thickness [4]. Numerous papers showed the technique being divided by the function of vibration frequencies: at a low frequency (under 100 Hz) in drilling [3,5,6] and in turning [7] and at ultrasonic frequencies both in milling [8,9] and in drilling [10].…”

Section: Introductionmentioning

confidence: 99%

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Predicted Torque Model in Low-Frequency-Assisted Boring (LFAB) Operations

Veiga¹,

Val²,

Penalva³

et al. 2021

Metals

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A low-frequency-assisted boring operation is a key cutting process in the aircraft manufacturing sector when drilling deep holes to avoid chip clogging based on chip breakage and, consequently, to reduce the temperature level in the cutting process. This paper proposes a predicted force model based on a commercial control-supported chip breaking function without external vibration devices in the boring operations. The model was fitted by conventional boring measurements and was validated by vibration boring experiments with different ranges of amplitude and frequency. The average prediction error is around 10%. The use of a commercial function makes the model more attractive for the industry because there is no need for intrusive vibration sensors. The low-frequency-assisted boring (LFAB) operations foster the chip breakage. Finally, the model is generic and can be used for different cutting materials and conditions. Roughness is improved by 33% when vibration conditions are optimal, considered as a vibration amplitude of half the feed per tooth. This paper presents, as a novelty, the analysis of low-frequency vibration parameters in boring processes and their effect on chip formation and internal hole roughness. This has a practical significance for the definition of a methodology based on the torque model for the selection of conditions on other hole-making processes, cutting parameters and/or materials.

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Section: Introductionmentioning

confidence: 99%

“…The tool oscillation opposite to the feed direction creates a loss of contact with the piece and, thus, interrupted machining occurs. In addition, fresh air enters in the tool-piece gap, decreasing tool temperature and, consequently, improving machining efficiency [5,6].…”

Section: Introductionmentioning

confidence: 99%

Predicted Torque Model in Low-Frequency-Assisted Boring (LFAB) Operations

Veiga¹,

Val²,

Penalva³

et al. 2021

Metals

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show abstract

“…The study provided very good agreement with the experimental readings. Schematic illustration of different elements on drill geometry is represented in Figure 1 [11]. Rotary ultrasonic elliptical machining (RUEM) is proved to be an alternative method to reduce delamination in drilling process for CFRP [12].…”

Section: Introductionmentioning

confidence: 99%

“…Schematic view of cutting geometry with cross sectional view at different selected elements (with kind permission from Elsevier[11]). …”

mentioning

confidence: 99%

Optimization of Cutting Process Parameters in Inclined Drilling of Inconel 718 Using Finite Element Method and Taguchi Analysis

2020

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Nickel-based superalloys are famous in the demanding applications. Inconel 718 is one of the most commonly used nickel-based superalloys due to its extraordinary inherent properties. Inconel 718 is a suitable material for high temperature applications due to the properties such as anti-oxidization, high hot hardness, high creep, and fatigue strength. Drilling operation is one of the most widely used manufacturing operations in almost all industrial sectors. However, drilling operation is very complex in nature due to the presence of intricate geometry of the drill bit. In conventional drilling, cutting is performed by the combined action of the chisel edge and the two or more cutting lips. In depth analysis of the cutting process shows that chisel edge starts with an indentation at the center of the twist drill. Then away from the center, chisel edge performs orthogonal cutting with negative rake angle. Whereas, cutting action at the cutting lip is oblique in nature, and force analysis involves the use of element formulation due to involvement of radius. It is rarely found in the literature where drilling operation at different inclination angles is conducted and analyzed. The presented study numerically investigates the cutting performance of drilling operation, when operated at different inclination angles. The study revealed cutting force variation at different inclination angles due to the different tool workpiece engagement for each inclination. The magnitude of thrust force increased when inclination angle is changed from 30° to 60°. It can be linked with the higher chip load initially in this case as compared to the 30° inclination angle. The cutting temperature was affected by spindle speed (53.7%), followed by feed rate (33.31%) and inclination angle (3.44%).

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“…Introduction: Adaptive intelligent control is a fundamental trend in manufacture including micro-deep hole drilling [1,2], existing drilling numerical control systems are usually designed only based on the static threshold of thrust force. Intelligent algorithms in drilling control need a large number of labelled test samples containing drilling forces and corresponding parameters, such as feed speed and spindle speed of drill bit, to establish an accurate dynamic relationship between drilling forces and drilling parameters, and then complex models for micro-deep hole drilling process are usually achieved to meet the needs of sample labelling [3,4]. In order to simplify and optimise the sample labelling, a four-dimensional (4D) measurement system for dynamic micro-deep hole drilling forces is designed, which is based on resistance strain gauge sensor and weak signal detection method, and can measure not only the drilling thrust force, but also tangential force and two orthogonal components of radial force precisely and stably in real time.…”

mentioning

confidence: 99%

Four‐dimensional dynamic force measurement system for micro‐deep hole drilling

Teng

Guan

et al. 2020

Electron. lett.

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An embedded micro-deep hole drilling force measurement system is proposed and verified experimentally, it is based on resistance strain gauge, weak signal detection method and embedded technology. The system can measure the thrust force, tangential force and two orthogonal components of radial force precisely, continuously and stably in real time, while other similar systems can measure only thrust force usually. The system can replace the complex modelling of drilling process to obtain random changing details of drilling forces, and can also be used effectively in intelligent drilling control research.

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Drilling force model for forced low frequency vibration assisted drilling of Ti-6Al-4V titanium alloy

Cited by 63 publications

References 34 publications

Predicted Torque Model in Low-Frequency-Assisted Boring (LFAB) Operations

Predicted Torque Model in Low-Frequency-Assisted Boring (LFAB) Operations

Optimization of Cutting Process Parameters in Inclined Drilling of Inconel 718 Using Finite Element Method and Taguchi Analysis

Four‐dimensional dynamic force measurement system for micro‐deep hole drilling

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