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Study on chip shapes in longitudinal-torsional composite ultrasonic vibration–assisted drilling of Ti-6Al-4V

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Abstract

Difficult-to break chips in the process of drilling Ti-6Al-4V, especially in micro-hole machining of aviation parts, are always considered a main negative result. Although the advantage of longitudinal ultrasonic vibration–assisted drilling (L-UAD) in improving chip breaking is widely concerned, studies on chip shapes in longitudinal-torsional composite ultrasonic vibration–assisted drilling (LTC-UAD) are seldom reported. In this study, kinematic analysis of LTC-UAD was carried out, and the motion trajectory of tool cutting edge was constructed. On this basis, the cutting thickness model is established, and the dynamic change law of cutting thickness is analyzed. Furthermore, the conditions for complete geometric chip breaking are explored, and the matching criteria of process parameters for complete geometric chip breaking are derived. To verify the theoretical analysis, machining experiments are performed, wherein good agreement is found between the experimental and theoretical results. The results show that LTC-UAD has obvious advantages over conventional drilling (CD) in breaking chips. Additionally, the influences of the vibration amplitude, spindle speed, and feed rate on chip shapes are analyzed, revealing that a large amplitude and small feed rate are beneficial to chip breaking. The proper spindle speed can also greatly promote the chip-breaking effect.

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Acknowledgements

The authors sincerely appreciate all the support.

Funding

This work was supported by the National Natural Science Foundation of China (U1804145).

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Authors and Affiliations

  1. School of Mechanical Engineering, Henan University of Science and Technology, Luoyang, 471003, China

    Yingjian Tian, Xiaoqiang Wang & Yuanfei Ling

  2. School of Mechanical Engineering and Automation, Northeastern University, Shenyang, 110819, China

    Ping Zou

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  1. Yingjian Tian
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Correspondence to Yingjian Tian.

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Tian, Y., Zou, P., Wang, X. et al. Study on chip shapes in longitudinal-torsional composite ultrasonic vibration–assisted drilling of Ti-6Al-4V. Int J Adv Manuf Technol 128, 5561–5571 (2023). https://doi.org/10.1007/s00170-023-12242-y

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  • DOI: https://doi.org/10.1007/s00170-023-12242-y

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