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Study on modal analysis and chip breaking mechanism of Inconel 718 by ultrasonic vibration-assisted drilling

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Abstract

In this study, both theoretical and experimental research was conducted to investigate the role played by a difficult-to-machine material, Inconel 718, in improving the surface finish quality in drilling holes. Ultrasonic vibration technology was applied to assist with the drilling process. An axial ultrasonic vibration-assisted drilling (UAD) system was designed to determine the structural relationships between different component parts, based on which an axial UAD model was established. Abaqus finite element software was applied to perform model simulation and an analysis was conducted of the structure to find its optimal natural frequency and vibration mode. The conditions for complete geometric chip breaking based on the mechanisms of UAD and chip breaking, as well as pre-set parameters, were inferred and the theoretical domain of complete geometric chip breaking was mapped. Subsequently, a range of different parameters was applied to conduct experiments on the drilling process, from which it was established that the characteristics of chipping satisfy the conditions required for complete geometric chip breaking. Finally, under the circumstances where the parameters for the drilling process are identical and chip breaking conditions are met, UAD was found to be advantageous over conventional drilling (CD) as the former produces a more apparent chip breaking effect. Additionally, UAD can reduce the Ra value and abrasion of cutting tools, thus improving the quality of the hole drilling process.

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Abbreviations

r :

Drill bit radius [mm]

Θ :

Rotation angle [rad]

f r :

Feed rate per revolution [mm/r]

A :

Amplitude [mm]

ω :

Angular velocity [rad/s]

n :

Rotary speed [r/min]

f :

Vibration frequency [Hz]

t :

Time [s]

φ :

Phase angle [rad]

V f :

Tool axial feed velocity [mm/s]

K :

Integer part

i :

Decimal part

s :

Chip thickness [mm]

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Funding

This project is supported by the National Natural Science Foundation of China (Grant No. 51875097).

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Authors and Affiliations

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

    Shuo Chen, Ping Zou, Yingjian Tian, Jingwei Duan & Wenjie Wang

  2. Department of Mechanical Engineering, Guidaojiaotong Polytechnic Institute, Shenyang, 110023, China

    Shuo Chen

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  1. Shuo Chen
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  2. Ping Zou
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  5. Wenjie Wang
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Correspondence to Ping Zou.

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

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  • DOI: https://doi.org/10.1007/s00170-019-04155-6

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