Ultrasonic assistance in drilling: FEM analysis and experimental approaches

چکیده مقاله

Conventional d rilling ( CD) which is known b y t wo con sta nt rotary an d linea r m otions cause s some problems i n drilling of materials such as high thrust force, poor surface quality, and rapid tool wear. To get rid of these pr oblems or at least minimize them, a p romi sing technology has been employed in the recent years, where vibrations usually with low a mpli tude and h igh f requen cy are a ppli ed to the di rection of feed motion results in a time-dependent velocity between drill t ip and w or kp iece. This pape r focus es on the design of a vibratory tool following by experimental and numerical ap-proaches to study the influenc e of l ongitudinal ultras onic vibra-ti ons o n dril ling o f a lum inum a lloy 7 075. Experi mental part is a comprehensive exercise to design, fabricat e, and test a system equipped with different instrument s to work in desired condi-tions. Experimental results are supported by a finite el ement method to better comprehend what is happening in cutting process when ultrasonic vibrations are added. The achieved resul ts prove that usi ng u ltrasonic-assisted drill ing (UAD ), the machi ni n g a bili ty of dril led aluminum wor kpiece can enhance significantly. I mprovement of up to 40% f or dr ill circular ity an d a r eduction of up to 37% i n thrust f orce were achieve d.