Abstract
Comparing to the conventional drilling (CD), vibration-assisted drilling (VAD) is a novel machining technique suitable for drilling in hard-to-machine materials such as carbon fiber-reinforced polymer (CFRP). However, the current VAD apparatuses are limit in the following vibration modes: one-dimensional longitude vibration and two-dimensional elliptic vibration, which both have the flaws for drilling in CFRP. In order to improve the VAD’s performance in the CFRP drilling, a novel variable-dimensional vibration-assisted drilling (VDVA) actuator is proposed, which can produce one-dimensional longitude vibration, two-dimensional elliptic vibration, and three-dimensional composite vibration, to adapt different machining phase in drilling FRP. One-dimensional longitude, three-dimensional composite, and two-dimensional elliptic vibration can be used in the entrance, middle, and export separately, which can improve drilling precision, chip capacity, and aperture accuracy and reduce the delamination and burr phenomena. Firstly, based on process requirements of drilling FRP, an actuator design method including piezoelectric transducer and horn design is proposed to establish the actuator model, which can be used to generate variable-dimensional vibration. Then, the system control for the proposed actuator is designed to output different vibration mode in actual drilling process. The resonant frequency and amplification ratios of the proposed actuator are analyzed by using FEA software. Based on the above analysis results, a prototype of the proposed actuator is fabricated, and then its vibration characteristics are evaluated by a micro-displacement sensor. With different phase sinusoidal driving voltages at different frequency of 20.7 and 5.8 kHz, the developed prototype achieved variable-dimensional vibration with one-dimensional longitude vibration of amplitude 11.0 μm, two-dimensional elliptic vibration of amplitudes 13.0 and 12.0 μm, and three-dimensional composite vibration of amplitudes 7.0, 10.8, and 12.1 μm. The experiments indicate that the performance of the developed actuator is satisfied, and the proposed actuator can be applied in composite material drilling process to improve the machining performance of composite material.
Similar content being viewed by others
References
Kishore KP, Kuppan P (2018) Drilling on fiber reinforced polymer/nanopolymer composite laminates: a review. J Mater Res Technol 7(2):180–189
Brinksmeier E, Janssen R (2002) Drilling of multi-layer composite materials consisting of carbon fiber reinforced plastics (CFRP), titanium and aluminum alloys. CIRP Ann Manuf Technol 51:87–90
Wang X, Kwon PY, Sturtevant C, Dave K, Jeff L (2013) Tool wear of coated drills in drilling CFRP. J Manuf Process 15(1):127–135
El-Hofy MH, Soo SL, Aspinwall DK, Sim WM, Pearson D, Harden P (2011) Factors affecting workpiece surface integrity in slotting of CFRP. Procedia Engineering 19(1):94–99
Tsao CC. Experimental study of drilling composite materials with step-core drill (2008) Mater Des 29(9):1740–1744
Gao H, Sun C, Wang Y (2016) Ultrasonic assisted helical milling experiment study on composites. Aeronautical Manufacturing Technol 498(3):16–20
Liu J, Chen G, Ji C, Qin X, Li H, Ren C (2014) An investigation of workpiece temperature variation of helical milling for carbon fiber reinforced plastics (CFRP). Int J Mach Tools Manuf 86(11):89–103
Bao Y (2012) Research on temperature field model during grinding-drilling of unidirectional carbon/epoxy composites. J Mechanical Engineering 48(1):169
Takeyama H, Iijima N (1988) Machinability of glass fiber reinforced plastics and application of ultrasonic machining. CIRP Ann Manuf Technol 37(1):93–96
Zhang DY, Wang LJ (1998) Investigation of chip in vibration drilling. Int J Mach Tools Manuf 38:165–176
Brehl DE, Dow TA (2008) Review of vibration-assisted machining. Precis Eng 32:153–172
Zhang C, Guo P, Ehmann KF, Li YG (2016) Effects of ultrasonic vibrations in micro-groove turning. Ultrasonics 67:30–40
Wang JJ, Zhang JF, Feng PF, Guo P (2018) Damage formation and suppression in rotary ultrasonic machining of hard and brittle materials: a critical review. Ceram Int 44:1227–1239
Wang X, Wang LJ, Tao JP (2004) Investigation on thrust in vibration drilling of fiber-reinforced plastics. J Mater Process Technol 148(2):239–244
Xu W, Zhang LC (2016) Mechanics of fibre deformation and fracture in vibration-assisted cutting of unidirectional fibre-reinforced polymer composites. Int J Mach Tools Manuf 103:40–52
Sadek A, Attia MH, Meshreki M, Shi B (2013) Characterization and optimization of vibration-assisted drilling of fibre reinforced epoxy laminates. CIRP Ann Manuf Technol 62:91–94
Ning FD, Cong WL, Pei ZJ, Treadwell C (2015) Rotary ultrasonic machining of CFRP: a comparison with grinding. Ultrasonics 66:125–132
Jin XL, Koya NG (2014) Investigation of warping effect on coupled torsional-axial vibration of drilling tool. Int J Mach Tools Manuf 86:2961–2974
Liu J, Zhang D, Qin L, Yan L (2012) Feasibility study of the rotary ultrasonic elliptical machining of carbon fiber reinforced plastics (CFRP). Int J Mach Tools Manuf 53(1):141–150
Xu S, Shimada K, Mizutani M, Kuriyagawa T (2017) Development of a novel 2D rotary ultrasonic texturing technique for fabricating tailored structures. Int J Adv Manuf Tech 89(1):1161–1172
Li ZQ, Zhang YQ (2013) A longitudinal-flexural coupling broadband tonpilz underwater transducer with double excitation. J Appl Acoustics 32(6):473–479
Funding
This paper was funded by the Natural Science Foundation of China under grant no. 51675277 and by the Natural Science Foundation of Jiangsu Province of China under grant no. BK20171415.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Zhang, C., Lu, M. A novel variable-dimensional vibration-assisted actuator for drilling CFRP. Int J Adv Manuf Technol 99, 3049–3063 (2018). https://doi.org/10.1007/s00170-018-2680-8
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-018-2680-8