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An optimization technique on ultrasonic and cutting parameters for drilling and deep drilling of nickel-based high-strength Inconel 738LC superalloy with deeper and higher hole quality

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Abstract

In this research work, an ultrasonic assisted drilling system is employed to apply both rotation and vibration to drill bits. The transducer horn transfers power very efficiently and changes tools effortlessly. The setup used to conduct drilling tests is Inconel 738LC with depth-to-diameter ratios from 2 to 10 by conventional drilling (CD), ultrasonic assisted drilling (UAD), and electro discharge drilling (EDD). The effects of ultrasonic vibration amplitude, spindle speed, and number of steps to drill each hole on machining force and surface roughness in UAD are investigated. The results demonstrate not only a significant improvement in tool life (by applying ultrasonic vibration to the drilling process) but also a 40 % reduction in thrust force compared to CD. The UAD technique seems more appropriate than the EDD method due to the ability to reduce machining process time by up to 90 %, improve cylindricity by roughly 50 %, increase hole dimension accuracy by up to 80 %, and reduce surface roughness by 52 %.

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Authors and Affiliations

  1. Center of Excellence in Design, Robotics and Automation, School of Mechanical Engineering, Sharif University of Technology, Tehran, Iran

    V. Baghlani, P. Mehbudi & J. Akbari

  2. Department of Mechanical Engineering, Hanyang University, 222 Wangsimni-ro, Seongdong-gu, Seoul, 133-791, South Korea

    Erfan Zal Nezhad

  3. Center of Advanced Manufacturing and Material Processing—Micro-Mechanism Research Group, Department of Engineering Design and Manufacture, University of Malaya, Kuala Lumpur, Malaysia

    Ahmed A. D. Sarhan

  4. Mechanical and Industrial Engineering Department, College of Engineering, Qatar University, 2713, Doha, Qatar

    A. M. S. Hamouda

Authors
  1. V. Baghlani
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  2. P. Mehbudi
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  3. J. Akbari
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  4. Erfan Zal Nezhad
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  5. Ahmed A. D. Sarhan
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  6. A. M. S. Hamouda
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Correspondence to Erfan Zal Nezhad.

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Baghlani, V., Mehbudi, P., Akbari, J. et al. An optimization technique on ultrasonic and cutting parameters for drilling and deep drilling of nickel-based high-strength Inconel 738LC superalloy with deeper and higher hole quality. Int J Adv Manuf Technol 82, 877–888 (2016). https://doi.org/10.1007/s00170-015-7414-6

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  • DOI: https://doi.org/10.1007/s00170-015-7414-6

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