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Study on the mechanism of AL2024-T351/Ti-6Al-4V laminated materials by ultrasonic vibration drilling

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Abstract

Conventional twist drills have problems such as large axial force, severe delamination, high temperature, and serious surface quality damage when drilling Al2024-T351/Ti-6Al-4V laminated materials. The main reason is that the low cutting performance of the drill bit in the conventional drilling (CD) process requires a higher axial force, and it also makes the drill bit wear serious. In order to solve these problems, special geometric tools are usually used for drilling and ultrasonic assisted drilling is added. This paper focuses on conventional drilling (CD) and ultrasonic-assisted drilling (UAD) drilling of multipoint drilling tools. The biggest difference between UAD and CD is that it exerts a certain frequency and amplitude vibration on the drill bit, which can make the drill bit go down with periodic axial vibration. Since the drilling motion curve is microscopically a sine curve, the breaking and removal of chips are accelerated during the drilling process, which is beneficial to improve the machining accuracy. Under the ideal experimental conditions, the drilling of laminated materials was explored through a combination of experiment and simulation. Experiments show that the use of geometric tools can improve the defects caused by twist drill processing, while the use of UAD can further improve the problems of large axial force, serious delamination, high temperature and serious surface quality damage. The tool wear is reduced and the hole surface accuracy is improved.

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Abbreviations

K AB :

Shear flow stress

h l :

Dynamic cutting thickness perpendicular to the working cutting plane

k r :

Main declination

λ s :

Blade inclination angle

η d :

Dynamic feed angle

ω :

Frequency

A :

Amplitude

f r :

Feed rate

n :

Rotation speed

γ nd :

Dynamic preangle of the micro-element dl at the radius r

γ fd :

Dynamic feed anterior angle

k rd :

Dynamic lead angle

γ n :

Pre-angle

ϕ nd :

Dynamic shear angle

λ sd :

Dynamic edge angle

η cd :

Dynamic flow chip angle

F S :

The shear force

F l :

The main edge axial force

β :

The helix angle

2p :

The apex angle

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Acknowledgements

The authors acknowledge the National Natural Science Foundation of China (No. 5217052158). In particular, the authors thank the editor and reviewers for their constructive suggestions.

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Author notes

  1. Shujing Wu & Dazhong Wang

    Present address: Shanghai University of Engineering Science, Shanghai, China

Authors and Affiliations

  1. Wuhan University, Wuhan, China

    Lei Wei

  2. Shanghai Spaceflight Precision Machinery Institute, Shanghai, China

    Guoqiang Guo

  3. SAIC Volkswagen Automotive Co., Ltd., Shanghai, China

    Shuqiao Zhang

  4. Qingdao University of Technology, Shanghai, China

    Changhe Li

  5. Shanghai Jiao Tong University, Qingdao, China

    Ming Chen

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  1. Shujing Wu
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Correspondence to Shujing Wu.

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Wu, S., Wei, L., Guo, G. et al. Study on the mechanism of AL2024-T351/Ti-6Al-4V laminated materials by ultrasonic vibration drilling. Archiv.Civ.Mech.Eng 22, 161 (2022). https://doi.org/10.1007/s43452-022-00482-w

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  • DOI: https://doi.org/10.1007/s43452-022-00482-w

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