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Investigation on a novel variant-dimension vibration-assisted drilling system for CFRP: locus model, control strategy, and machining experiments

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Abstract

Ultrasonic vibration-assisted drilling, which can obtain the minimization of geometrical defects, provides a solution for the drilling of carbon fiber-reinforced plastic (CFRP) by adding a displacement of a micro-scale amplitude with a frequency to the tool tip. However, single vibration mode in drilling of CFRP cannot satisfy the different requirements of various drilling stages in CFRP and limits the applications of current ultrasonic vibration-assisted drilling of CFRP. To overcome the limitation and improve the performance of vibration-assisted drilling process in CFRP components, a novel variant-dimension vibration-assisted drilling system (VD-VADS) is proposed. The VD-VADS is specially designed to be capable of delivering variant-dimension vibrations at the tool tip for drilling holes in CFRP by producing one-dimension longitude vibration, two-dimension elliptic vibration, and three-dimension composite vibration, which can be transferred to adapt to various drilling stages in CFRP. An analytical model of the VD-VADS’s locus will be formulated to facilitate the prediction of the loci of the tooltip and design and realization of the prototype device. The control strategy of variant-dimension vibration mode of the proposed VD-VADS is established and realized for various drilling stages in CFRP. To validate the machining performance of the VD-VADS, five groups of drilling experiments under the conventional drilling and various vibration-assisted drilling processes were performed. The performance tests and comparison results of the obtained holes between the conventional drilling and various vibration-assisted drilling processes indicate that the proposed VD-VADS is capable of generating holes with better overall quality than the current single vibration-assisted drilling processes.

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Funding

This paper was funded by the Natural Science Foundation of China (NSFC) under grant no 51675277 and by the High-Level Talents Project of “six talents summit” in Jiangsu under grant number GDZB-011.

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Authors and Affiliations

  1. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, China

    Chen Zhang & Ming Lu

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  1. Chen Zhang
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  2. Ming Lu
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Contributions

The contribution of this paper is that the VD-VADS is specially designed to be capable of delivering variant-dimension vibrations at the tool tip for drilling holes in CFRP by producing one-dimension longitude vibration, two-dimension elliptic vibration, and three-dimension composite vibration, which can be transferred to adapt to various drilling stages in CFRP and an analytical model of the VD-VADS’s locus will be formulated to facilitate the prediction of the loci of the tooltip and design and realization of the prototype device. The control strategy of variant-dimension vibration mode of the proposed VD-VADS is established and realized for various drilling stages in CFRP.

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Correspondence to Chen Zhang.

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Zhang, C., Lu, M. Investigation on a novel variant-dimension vibration-assisted drilling system for CFRP: locus model, control strategy, and machining experiments. Int J Adv Manuf Technol 113, 2629–2650 (2021). https://doi.org/10.1007/s00170-021-06744-w

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  • DOI: https://doi.org/10.1007/s00170-021-06744-w

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