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Mathematical modeling and experimental studies on axial drilling load for rotary ultrasonic drilling of C/SiC composites

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A Correction to this article was published on 23 June 2020

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Abstract

Ceramic matrix composites of type C/SiC have great potential in space applications because of their superior properties such as low density, high wear resistance, and high-temperature resistance. However, due to their heterogeneous, anisotropic, and unstable thermal properties, the machining is still challenging to achieve desired efficiency and quality. For advanced materials, rotary ultrasonic machining (RUM) is considered as a highly efficient technology. Predicting mechanical load in RUM can help to optimize input variables and reduce processing defects in composites. In this research, a mathematical axial drilling load (force and torque) model has been developed based on the indentation fracture theory of material removal mechanism considering penetration trajectory and energy conservation theorem for rotary ultrasonic drilling (RUD) of C/SiC. Experiments were conducted on C/SiC composites to validate the model, and experimental results agreed well with model predictions with less than 14% (force) and 10% (torque) error. Therefore, this theoretical model can be effectively applied to predict axial drilling load during RUD of C/SiC. The relationships of axial drilling force and torque with machining process parameters, including spindle speed, feed rate, and ultrasonic power, were investigated. A specific range of experiments was carried out to demonstrate the benefit of ultrasonic vibration in RUD over conventional drilling (CD) on mechanical load for a designed drilling tool. It was noticed that RUD outperformed CD with a maximum of 38.11% and 34.30% in axial drilling force and torque reduction, respectively. The influence of drilling tool flute length on drilling performance was also elucidated based on a set of experiments using several designed drilling tools.

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Change history

  • 23 June 2020

    Fig. 2,��Eq. (8), and Eq. (26) have been updated.

Abbreviations

CMC :

Ceramic matrix composites

C/SiC :

Carbon fiber reinforced silicon carbide matrix composites

RUM :

Rotary ultrasonic machining

RUD :

Rotary ultrasonic drilling

PCD :

Polycrystalline diamond

R :

Distance of an abrasive particle from the center of drilling tool (mm)

R 1 :

Inner radius of drilling tool (mm)

R 2 :

Outer radius of drilling tool (mm)

w ′ :

Instantaneous penetration depth (μm)

w max :

Maximum penetration depth of a diamond abrasive particle (μm)

b 1 :

The slope of the simplified straight line of penetration trajectory

F n ′ :

Instantaneous axial drilling force applied to one abrasive (N)

F n :

Average axial drilling force of a single abrasive particle (N)

F N :

Normal drilling force (N)

F T :

Tangential drilling force (N)

F s :

Simulated axial drilling force according to the mathematical model (N)

F m :

Measured axial drilling force according to the experiments (N)

T s :

Simulated axial drilling torque according to the mathematical model (N·mm)

T m :

Measured axial drilling torque according to the experiments (N·mm)

H v :

Vickers hardness of the workpiece material (GPa)

μ :

Frictional coefficient of the workpiece material

K IC :

Fracture toughness of the workpiece material (MPa·m1/2)

E :

Elastic modulus of the workpiece material (GPa)

ν :

Poisson’s ratio of the workpiece material

V s :

Volume of a single diamond abrasive particle (mm3)

V 0 :

Theoretical material removal volume of fracture zone (mm3)

V :

Actual material removal volume by one diamond abrasive (mm3)

MRR a :

Material removal rate of a single diamond abrasive particle (mm3/s)

MRR T :

Material removal rate of a drilling tool (mm3/s)

β :

Half-angle between two opposite edge of an abrasive particle (deg)

d :

Penetration width (μm)

S a :

Side length of a single diamond abrasive particle (μm)

N α :

Total number of diamond abrasive particles involved in drilling

C α :

Concentration of the diamond abrasive particles on a drilling tool

ρ :

Density of the diamond abrasive particles (g/cm3)

A 0 :

Contact area of the drilling tool involved in drilling (mm2)

z :

Trajectory of the diamond abrasive particles

A :

Amplitude of the ultrasonic vibration (μm)

f :

Frequency of the ultrasonic vibration (Hz)

t :

Drilling time (s)

Δt :

Effective contact time in a vibration cycle (s)

I :

Impulse during one ultrasonic vibration cycle (N·s)

C L :

Length of lateral crack (μm)

C h :

Depth of lateral crack (μm)

L s :

Effective cutting distance (μm)

S :

Spindle speed (rpm)

f r :

Feed rate (mm/min)

P :

Ultrasonic power (w)

K :

Correction coefficient of axial drilling load

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Funding

This research was financially supported by the National Natural Science Foundation of China (Grant No. U1737201). The authors are indebted to this financial support to accomplish this research work.

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Authors and Affiliations

  1. Beijing Engineering Technological Research Center of High-efficient & Green CNC Machining Process and Equipment, School of Mechanical Engineering and Automation, Beihang University, Beijing, 100191, China

    Shafiul Islam, Songmei Yuan & Zhen Li

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  1. Shafiul Islam
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  2. Songmei Yuan
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  3. Zhen Li
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Correspondence to Shafiul Islam or Songmei Yuan.

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Islam, S., Yuan, S. & Li, Z. Mathematical modeling and experimental studies on axial drilling load for rotary ultrasonic drilling of C/SiC composites. Int J Adv Manuf Technol 107, 1309–1326 (2020). https://doi.org/10.1007/s00170-020-05052-z

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