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Modeling of burr height in ultrasonic-assisted drilling of DD6 superalloy

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Abstract

DD6 nickel-based superalloy is a typical refractory material, and has important applications in the aviation industry. Ultrasonic-assisted drilling can greatly enhance the processability of refractory materials. The presence of burrs will affect assembly, and the extra process to remove burrs will reduce production efficiency and increase production costs. Compared with conventional drilling, ultrasonic-assisted drilling can distinctly reduce the burr height. It is very necessary to model and predict the burr height of ultrasonic-assisted drilling. A prediction model of exit burr for ultrasonic-assisted micro drilling is proposed. A new thrust force model is developed by considering the dynamic cutting speed, dynamic cutting thickness, and the acoustic softening effect. The newly established ultrasonic-assisted drilling thrust force model was used to modify the conventional drilling burr height model, and the burr height was calculated. The accuracy of the model is verified by ultrasonic-assisted drilling experiments under different feed rates, spindle speeds, frequencies, amplitudes, and point angles of the bit. The minimum error of the average burr height prediction value is 4.5%, and the maximum error is 17.7%. The model has great significance in the prediction of burr height in ultrasound-assisted micro-hole drilling.

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Data availability

All authors confirm that the data supporting the findings of this study are available within the article.

Abbreviations

f z :

Feed per revolution (mm/r)

n :

Spindle speed (r/s)

t :

Time (s)

f :

Vibration frequency (Hz)

A :

Amplitude (μm)

t a :

Axial uncut chip thickness (mm)

t i :

Instantaneous uncut chip thickness (mm)

ϕ:

Half-point angle (°)

r :

Radial distance of the drill bit (mm)

h :

Helix angle (°)

F n :

Normal force (N)

F f :

Friction force (N)

A c :

Area of the uncut chip (mm2)

K n :

Specific normal force (N/mm2)

K f :

Specific friction force (N/mm2)

v c :

Cutting speed (mm/s)

α n :

Normal rake angle (°)

i :

Inclination angle (°)

l chi :

Length of the chisel edge (mm)

ηc :

Chip flow angle (°)

ψ:

Chisel edge angle (°)

dF mcut :

Elemental cutting force in main cutting edge (N)

dF mthu :

Elemental oblique cutting thrust force in main cutting edge (N)

dF mlat :

Elemental lateral force in main cutting edge (N)

dF ccut :

Elemental cutting force in chisel edge (N)

dF cthu :

Elemental thrust force in chisel edge (N)

v p :

Poisson’s ratio of the workpiece material

ω:

Circular frequency (rad/s)

s :

Wave velocity

E :

Young’s modulus

F r c cin :

Reduction in indentation force (N)

k :

Constant related to material

F ccin :

Indentation force in conventional drilling (N)

F zTotal :

Total thrust force in ultrasonic assisted drilling (N)

F cin :

Indentation force in ultrasonic assisted drilling (N)

f(t):

Instantaneous feed rate (mm/s)

ΔW T :

Total work

ΔW th :

Work for drilling

ΔW df :

Work for material deformation

h 0 :

Critical thickness (mm)

R :

Radius of the bit (mm)

εab :

Logarithmic strain

V :

Volume of the deformed material (mm3)

σy :

Yield strength (Mpa)

Δθ:

Bending angle (rad)

εp :

Effective plastic strain

εf :

Fracture strain

H :

Burr height (mm)

%R.A. :

Percentage of material area reduction at tensile fracture

SP :

Sensitivity percentage

Δf(x i):

Change rate of burr height

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Funding

This work is supported by National Natural Science Foundation of China (Grant No. 51775443), National Science and Technology Major Project (Grant No. 2017-VII-0015–0111), and China Postdoctoral Science Foundation (Grant No. 2020M683569). National Natural Science Foundation of China,51775443,Wenhu Wang,National Science and Technology Major Project,2017-VII-0015–0111,Wenhu Wang,China Postdoctoral Science Foundation,2020M683569,Yifeng Xiong

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Authors and Affiliations

  1. Key Laboratory of High Performance Manufacturing for Aero Engine, Ministry of Industry and Information Technology, School of Mechanical Engineering, Northwestern Polytechnical University, Xi’an, 710072, Shaanxi, People’s Republic of China

    Xiaoxiang Zhu, Wenhu Wang, Yifeng Xiong & Xiaofen Liu

  2. Engineering Research Center of Advanced Manufacturing Technology for Aero Engine, Ministry of Education, School of Mechanical Engineering, Northwestern Polytechnical University, Xi’an, 710072, Shaanxi, People’s Republic of China

    Xiaoxiang Zhu, Wenhu Wang, Yifeng Xiong & Xiaofen Liu

  3. School of Aeronautics and Astronautics, Sichuan University, Chengdu, 610065, Sichuan, People’s Republic of China

    Ruisong Jiang

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  1. Xiaoxiang Zhu
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  2. Wenhu Wang
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  3. Ruisong Jiang
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  4. Yifeng Xiong
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  5. Xiaofen Liu
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Contributions

Xiaoxiang Zhu: experiment and manuscript writing. Wenhu Wang: project administration and funding acquisition. Ruisong Jiang: review and editing. Yifeng Xiong: review and editing. Xiaofen Liu: review and editing.

Corresponding author

Correspondence to Yifeng Xiong.

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Zhu, X., Wang, W., Jiang, R. et al. Modeling of burr height in ultrasonic-assisted drilling of DD6 superalloy. Int J Adv Manuf Technol 120, 2167–2181 (2022). https://doi.org/10.1007/s00170-021-08524-y

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  • DOI: https://doi.org/10.1007/s00170-021-08524-y

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