Skip to main content
SpringerLink
Log in

Experimental investigation on cavitation effect and surface quality of ultrasonic-assisted micro-hole drilling

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Ultrasonic-assisted drilling technology (UAD) is an advanced processing method that combines conventional drilling (CD) and ultrasonic-assisted machining, which can improve the machinability of difficult-to-process materials. In this work, UAD micro-hole machining was studied on AISI 4340 steel. Combined with the intersection characteristics of the dynamic trajectory, the chip breaking ability of the cutting edge was analyzed. The influence of processing parameters (spindle speed, feed rate, and amplitude) on the chip shape, chip removal effect, surface quality, and thrust force was studied. The results showed that the chips were mainly the continuous helical shape in CD, while the chips in UAD were mainly fan-shaped and finely broken. In UAD, the ultrasonic cavitation effect significantly promoted the discharge of fine chips. When the ultrasonic vibration was applied, compared with CD, the thrust force in UAD was reduced by 7% to 25.3%. In CD, the size and distribution density of surface defects were more severe than UAD. Compared with CD, the surface roughness of the wall surface in UAD was reduced by 19.2% to 32.4%. When the amplitude was increased to 4.5 μm, the wall surface was smoother without processing marks, and the roughness was reduced by 18.6%. The research is expected to guide the high-quality and high-efficiency manufacturing of micro-holes in difficult-to-machine materials.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18

Similar content being viewed by others

Data availability

All the data have been presented in the manuscript.

References

  1. Gopikrishnan P, Akbar A, Asokan A, Bhaskar B, Sumesh CS (2018) Numerical modelling and optimization of surface finish during peripheral milling of AISI 4340 steel using RSM. Mater Today Proc 5:24612–24621. https://doi.org/10.1016/j.matpr.2018.10.259

    Article  Google Scholar 

  2. Bin RW, Goel S, Luo X, Ritchie JM (2013) The development of a surface defect machining method for hard turning processes. Wear 302:1124–1135. https://doi.org/10.1016/j.wear.2013.01.048

    Article  Google Scholar 

  3. Perçin M, Aslantas K, Ucun I, Kaynak Y, Çicek A (2016) Micro-drilling of Ti-6Al-4V alloy: the effects of cooling/lubricating. Precis Eng 45:450–462. https://doi.org/10.1016/j.precisioneng.2016.02.015

    Article  Google Scholar 

  4. Butler-Smith PW, Axinte DA, Daine M, Kennedy AR, Harper LT, Bucourt JF, Ragueneau R (2015) A study of an improved cutting mechanism of composite materials using novel design of diamond micro-core drills. Int J Mach Tools Manuf 88:175–183. https://doi.org/10.1016/j.ijmachtools.2014.10.002

    Article  Google Scholar 

  5. Hasan M, Zhao J, Jiang Z (2017) A review of modern advancements in micro drilling techniques. J Manuf Process 29:343–375. https://doi.org/10.1016/j.jmapro.2017.08.006

    Article  Google Scholar 

  6. Zhu XX, Wang WH, Jiang RS, Zhang ZF, Huang B, Ma XW (2020) Research on ultrasonic-assisted drilling in micro-hole machining of the DD6 superalloy. Adv Manuf 8:405–417. https://doi.org/10.1007/s40436-020-00301-6

    Article  Google Scholar 

  7. Chen S, Zou P, Tian Y, Duan J, Wang W (2019) Study on modal analysis and chip breaking mechanism of Inconel 718 by ultrasonic vibration-assisted drilling. Int J Adv Manuf Technol 105:177–191. https://doi.org/10.1007/s00170-019-04155-6

    Article  Google Scholar 

  8. Li Z, Zhang D, Jiang X, Qin W, Geng D (2017) Study on rotary ultrasonic-assisted drilling of titanium alloys (Ti6Al4V) using 8-facet drill under no cooling condition. Int J Adv Manuf Technol 90:3249–3264. https://doi.org/10.1007/s00170-016-9593-1

    Article  Google Scholar 

  9. Kumar MN, Subbu SK, Krishna PV, Venugopal A (2014) Vibration assisted conventional and advanced machining: a review. Procedia Eng 97:1577–1586. https://doi.org/10.1016/j.proeng.2014.12.441

    Article  Google Scholar 

  10. Zhang Z, Babitsky VI (2011) Finite element modeling of a micro-drill and experiments on high speed ultrasonically assisted micro-drilling. J Sound Vib 330:2124–2137. https://doi.org/10.1016/j.jsv.2010.12.025

    Article  Google Scholar 

  11. Aziz M, Ohnishi O, Onikura H (2012) Novel micro deep drilling using micro long flat drill with ultrasonic vibration. Precis Eng 36:168–174. https://doi.org/10.1016/j.precisioneng.2011.07.010

    Article  Google Scholar 

  12. Gao G, Xia Z, Yuan Z, Xiang D, ZHAO B (2021) Influence of longitudinal-torsional ultrasonic-assisted vibration on micro-hole drilling Ti-6Al-4V. Chinese J Aeronaut 34:247–260. https://doi.org/10.1016/j.cja.2020.06.012

    Article  Google Scholar 

  13. Shan C, Zhang X, Dang J, Yang Y (2018) Rotary ultrasonic drilling of needle-punched carbon/carbon composites: comparisons with conventional twist drilling and high-speed drilling. Int J Adv Manuf Technol 98:189–200. https://doi.org/10.1007/s00170-017-1228-7

    Article  Google Scholar 

  14. Barani A, Amini S, Paktinat H, Fadaei Tehrani A (2014) Built-up edge investigation in vibration drilling of Al2024-T6. Ultrasonics 54:1300–1310. https://doi.org/10.1016/j.ultras.2014.01.003

    Article  Google Scholar 

  15. Azarhoushang B, Akbari J (2007) Ultrasonic-assisted drilling of Inconel 738-LC. Int J Mach Tools Manuf 47:1027–1033. https://doi.org/10.1016/j.ijmachtools.2006.10.007

    Article  Google Scholar 

  16. Lv D, Zhang Y, Peng Y (2016) High-frequency vibration effects on hole entrance chipping in rotary ultrasonic drilling of BK7 glass. Ultrasonics 72:47–56. https://doi.org/10.1016/j.ultras.2016.07.011

    Article  Google Scholar 

  17. Onawumi PY, Roy A, Silberschmidt VV, Merson E (2018) Ultrasonically assisted drilling of aerospace CFRP/Ti stacks. Procedia CIRP 77:383–386. https://doi.org/10.1016/j.procir.2018.09.041

    Article  Google Scholar 

  18. Yarar E, Karabay S (2020) Investigation of the effects of ultrasonic assisted drilling on tool wear and optimization of drilling parameters. CIRP J Manuf Sci Technol 31:265–280. https://doi.org/10.1016/j.cirpj.2020.06.002

    Article  Google Scholar 

  19. Lauterborn W, Kurz T, Geisler R, Schanz D, Lindau O (2007) Acoustic cavitation, bubble dynamics and sonoluminescence. Ultrason Sonochem 14:484–491. https://doi.org/10.1016/j.ultsonch.2006.09.017

    Article  Google Scholar 

  20. Liew PJ, Yan J, Kuriyagawa T (2014) Fabrication of deep micro-holes in reaction-bonded SiC by ultrasonic cavitation assisted micro-EDM. Int J Mach Tools Manuf 76:13–20. https://doi.org/10.1016/j.ijmachtools.2013.09.010

    Article  Google Scholar 

  21. Ghiculescu D, Niculae NI, Jitianu G, Seritan G (2009) On precision improvement by ultrasonics-aided electrodischarge machining. Est J Eng 15:24. https://doi.org/10.3176/eng.2009.1.03

    Article  Google Scholar 

  22. Ghiculescu D, Marinescu NI, Nanu S (2008) Influence of macro and microgeometry machined surface on ultrasonic aided electrodischarge machining. Int J Mater Form 1:1339–1342. https://doi.org/10.1007/s12289-008-0111-3

    Article  Google Scholar 

  23. Dular M (2016) Hydrodynamic cavitation damage in water at elevated temperatures. Wear 346–347:78–86. https://doi.org/10.1016/j.wear.2015.11.007

    Article  Google Scholar 

  24. Ye L, Zhu X, He Y, Song T, HU W (2021) Surface strengthening and grain refinement of AZ31B magnesium alloy by ultrasonic cavitation modification. Chinese J Aeronaut 34:508–517. https://doi.org/10.1016/j.cja.2020.08.043

    Article  Google Scholar 

  25. Bai F, Long Y, Saalbach K, Twiefel J (2019) Theoretical and experimental investigations of ultrasonic sound fields in thin bubbly liquid layers for ultrasonic cavitation peening. Ultrasonics 93:130–138. https://doi.org/10.1016/j.ultras.2018.11.010

    Article  Google Scholar 

  26. Li Z, Xu Z, He P, Ma Z, Chen S, Yan J (2021) Dependence of wetting on cavitation during the spreading of a filler droplet on the ultrasonically agitated Al substrate. Ultrason Sonochem 82:105893. https://doi.org/10.1016/j.ultsonch.2021.105893

    Article  Google Scholar 

  27. Bai F, Wang L, Yang K, He Z, Liu C, Twiefel J (2021) A novel inner surface enhancement method for holes utilizing ultrasonic cavitation. Ultrasonics 115:106453. https://doi.org/10.1016/j.ultras.2021.106453

    Article  Google Scholar 

  28. Chahine GL (2014) Modeling of cavitation dynamics and interaction with material. Fluid Mech Appl 123–161

  29. Amini S, Paktinat H, Barani A, Tehran AF (2013) Vibration drilling of Al2024-T6. Mater Manuf Process 28:476–480. https://doi.org/10.1080/10426914.2012.736659

    Article  Google Scholar 

Download references

Funding

This work was supported by the National Natural Science Foundation of China (U19A20103); Jilin Province Key Scientific and Technological Project (20200401070GX); Fund for Equipment Pre-Research (61409230115); and the “111” Project of China (No. D17017).

Author information

Authors and Affiliations

  1. Ministry of Education Key Laboratory for Cross-Scale Micro and Nano Manufacturing, Changchun University of Science and Technology, Changchun, 130022, China

    Guangjun Chen, Jinkai Xu, Jingdong Wang, Ying Li, Jiaqi Wang & Huadong Yu

Authors
  1. Guangjun Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Jinkai Xu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Jingdong Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Ying Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Jiaqi Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Huadong Yu
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding authors

Correspondence to Jingdong Wang or Huadong Yu.

Ethics declarations

Conflict of interest

The authors declare no competing interests.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Supplementary information

Below is the link to the electronic supplementary material.

Supplementary file1 (MP4 14274 KB)

Supplementary file2 (MP4 14717 KB)

Supplementary file3 (MP4 11907 KB)

Supplementary file4 (MP4 8240 KB)

Supplementary file5 (MP4 13150 KB)

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Chen, G., Xu, J., Wang, J. et al. Experimental investigation on cavitation effect and surface quality of ultrasonic-assisted micro-hole drilling. Int J Adv Manuf Technol 121, 919–936 (2022). https://doi.org/10.1007/s00170-022-09193-1

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-022-09193-1

Keywords

Search

Navigation