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Experimental research on new hole-making method assisted with asynchronous mixed frequency vibration in TiBw/TC4 composites

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Abstract

With the gradual promotion and the application of difficult-to-machine materials such as titanium matrix composites in the aerospace field, high-quality hole-making technology has become a major demand in aviation manufacturing. In order to improve the hole-making quality of TiBw/TC4 composites, asynchronous mixed frequency vibration-assisted hole-making (AMFVAHM) method is proposed. The process consists of two steps: ultrasonic vibration-assisted drilling (UVAD) base hole and low-frequency torsional vibration-assisted helical milling (LFTVAHM) target hole. Based on this process, the cutting trajectory modeling is established, and the hole-making experiment on TiBw/TC4 composites is conducted. The experimental data show that during the hole expansion stage, the maximum XY-plane average milling force decreases by 30.96% and the maximum axial average milling force decreases by 24.49% compared with conventional helical milling (HM) when the torsional vibration frequency and the milling frequency are the same in LFTVAHM. The hole-making experiment shows that AMFVAHM can reduce the chip size, tool wear, and some other defects such as entrance/exit burrs, scratches, and fractures of the hole wall. Comparing with HM and UVAD, the verticality of hole wall increases by 71.43% and 86.21%, the inlet damage decreases by 27.98% and 31.60%, the outlet damage decreases by 2.80% and 14.47%, the hole wall roughness (Ra) decreases by 36.29% and 63.43%, and the maximum white layer thickness decreases by 19.99% and 67.66%. Meanwhile, AMFVAHM process not only reduces the cutting force and cutting temperature but also improves the hole-making quality due to the fretting friction effect of LFTVAHM in secondary hole expansion, which meets the need for high-quality hole-making of difficult-to-machine materials in practical engineering applications.

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Data availability

The datasets generated during and/or analyzed during the current study are not publicly available, but are available from the corresponding author on reasonable request.

Code availability

The code that supports the findings of this study is available from the corresponding author upon request.

Abbreviations

D 1 :

Base hole diameter (mm)

d 1 :

Twist drill diameter (mm)

r 1 :

Twist drill radius (mm)

ρ 1 :

Ultrasonic vibration range (μm)

A 1 :

Ultrasonic vibration amplitude (μm)

f 1 :

Ultrasonic vibration frequency (Hz)

t :

Time (s)

D 2 :

Target hole diameter (mm)

R 2 :

Target hole radius (mm)

d 2 :

End mill diameter (mm)

r 2 :

End mill radius (mm)

ρ 2 :

Low-frequency torsional vibration angle (rad)

A 2 :

Low-frequency torsional vibration amplitude (rad)

f 2 :

Low-frequency torsional vibration frequency (Hz)

O T X T Y T Z T :

UVAD 3D cutter coordinate system

n 1 :

Rotation speed of twist drill (r/min)

θ :

Rotation angle of twist drill (rad)

f v :

Feed speed of twist drill (mm/min)

r :

Radius from point OT to point A1 (mm)

O W X W Y W :

LFTVAHM 2D workpiece coordinate system

O C X C Y C :

LFTVAHM 2D cutter coordinate system

e :

End mill eccentricity (mm)

α :

Angle of rotation of point B relative to OCXCYC without torsional vibration (rad)

β :

The angle of OCXCYC relative to OWXWYW revolution without torsional vibration (rad)

f t :

Feed per tooth of the end mill (mm/tooth)

N :

End mill revolution speed (r/min)

a p :

Lead pitch (mm/rev)

z :

End mill tooth number

F TZ :

Total axial force of LFTVAHM (N)

T :

Reversed actual temperature (°C)

U :

Voltage measured (mV)

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Funding

This research was funded by the National Natural Science Foundation of China (no. 51775260), the Natural Science Foundation of the Jiangsu Higher Education Institutions of China (21KJB460022), and Scientific Research Foundation for High-level Talents of Nanjing Institute of Technology (YKJ202004).

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Authors and Affiliations

  1. School of Mechanical Engineering, Nanjing Institute of Technology, Nanjing, 211167, Jiangsu, China

    Haojie Zhou, Yong Feng, Weiwei Xu, Zhiyuan Zhou, Yuyan Qin & Xiaolin Jia

  2. School of Mechanical Engineering, Changshu Institute of Technology, Suzhou, 215506, Jiangsu, China

    Yong Feng

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  1. Haojie Zhou
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  2. Yong Feng
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  3. Weiwei Xu
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  4. Zhiyuan Zhou
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  5. Yuyan Qin
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  6. Xiaolin Jia
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All authors contributed to the study conception and design. All authors read and approved the final manuscript.

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Correspondence to Yong Feng.

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Zhou, H., Feng, Y., Xu, W. et al. Experimental research on new hole-making method assisted with asynchronous mixed frequency vibration in TiBw/TC4 composites. Int J Adv Manuf Technol 125, 543–561 (2023). https://doi.org/10.1007/s00170-022-10754-7

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  • DOI: https://doi.org/10.1007/s00170-022-10754-7

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