Study on rotary ultrasonic-assisted drilling of titanium alloys (Ti6Al4V) using 8-facet drill under no cooling condition

Li, Zhe; Zhang, Deyuan; Jiang, Xinggang; Qin, Wei; Geng, Daxi

doi:10.1007/s00170-016-9593-1

Cited by 73 publications

(29 citation statements)

References 27 publications

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“…Using design of experiment methods, such as Taguchi and response surface, showed that feed rate and cutting speed are the most influential parameters on the drilling of steels. Different machining methods, such as ultrasonic drilling, and tool selection leads to better surface quality and drilling of soft materials, such as Al, and helical milling increases fatigue life [ 18 , 19 , 20 ]. The effect of pre-hole drilling on Al 6061-7075 with uncoated HSS drills showed that pre-holes reduce cutting force and improve surface roughness and chip generation [ 21 ].…”

Section: Introductionmentioning

confidence: 99%

Investigation on the Effect of a Pre-Center Drill Hole and Tool Material on Thrust Force, Surface Roughness, and Cylindricity in the Drilling of Al7075

2018

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Drilling is one of the most useful metal cutting processes and is used in various applications, such as aerospace, electronics, and automotive. In traditional drilling methods, the thrust force, torque, tolerance, and tribology (surface roughness) are related to the cutting condition and tool geometry. In this paper, the effects of a pre-center drill hole, tool material, and drilling strategy (including continuous and non-continuous feed) on thrust force, surface roughness, and dimensional accuracy (cylindricity) have been investigated. The results show that using pre-center drill holes leads to a reduction of the engagement force and an improvement in the surface quality and cylindricity. Non-continuous drilling reduces the average thrust force and cylindricity value, and High Speed Steels HSS-Mo (high steel speed + 5–8% Mo) reduces the maximum quantity of cutting forces. Moreover, cylindricity is directly related to cutting temperature and is improved by using a non-continuous drilling strategy.

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Section: Introductionmentioning

confidence: 99%

Investigation on the Effect of a Pre-Center Drill Hole and Tool Material on Thrust Force, Surface Roughness, and Cylindricity in the Drilling of Al7075

2018

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“…2 In 1964, the British scholar Legge proposed an ultrasonic machining method without abrasive slurry, which combined traditional ultrasonic machining with grinding machining; this method proved efficient and improved the material removal rate over traditional ultrasonic machining, 3 as shown in Figure 1. When the cutting tool for grinding is replaced with a drill, a milling cutter, or other cutting tools, the method is usually referred to as ultrasonic-assisted machining, such as ultrasonic-assisted drilling 4 and ultrasonic-assisted milling. 5 Recently, due to increasing demand for applications of hard and brittle materials, such as optical glass, sapphires, ceramics, and ceramic matrix/reinforced phase composites in aerospace, national defense, military, and electronic information, high-efficiency and lowdamage machining methods suitable for these materials have also attracted increasing attention.…”

Section: Introductionmentioning

confidence: 99%

Advances in rotary ultrasonic machining system for hard and brittle materials

Zhou

Zhang

et al. 2019

Advances in Mechanical Engineering

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Rotary ultrasonic machining has been widely used for machining of hard and brittle materials due to the advantages of low cutting force, high machining accuracy, and high surface integrity. Focusing on the development of specialized rotary ultrasonic machining systems, this article summarizes the advances in the functional components and key technologies of rotary ultrasonic machining systems for hard and brittle materials, including the ultrasonic generator, power transfer structure, transducer, ultrasonic horn, and cutting tool. Developments on the automatic frequency tracking method, the establishment of an electrical compensation model for power transfer, the energy conversion characteristics of piezoelectric materials and giant magnetostrictive materials, and the design methods for the ultrasonic horn and cutting tool were elaborated. The principle of magnetostrictive energy conversion, output amplitude characteristics of a giant magnetostrictive transducer, and high-power giant magnetostrictive rotary ultrasonic machining systems were also presented. Future research and developments of rotary ultrasonic machining systems regarding the ultrasonic generator, amplitude stability, energy conversion efficiency, vibration mode, and system integration were finally discussed.

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“…10 Moreover, the effects of key machining parameters on the cutting force and surface roughness were estimated based on FEM. [11][12][13][14] And both experimental and finite-element-based approaches were adopted to research the effect of coated textured tools on cutting performance. 15 FEM was also used to study deep drawing process of SUS304 cups without delayed cracks, 16 the dynamic process for machining of slip-cast fused silica ceramics, 17 and multi-pass non-axisymmetric spinning of cylindrical parts.…”

Section: Introductionmentioning

confidence: 99%

Fatigue failure analysis of ceramic tools in intermittent cutting harden steel based on experiments and finite element method

Zhao

Gong

et al. 2019

Proceedings of the Institution of Mechanical Engineers, Part B:

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The major concern of this article is the fatigue failure mechanisms of ceramic cutting tools with the help of intermittent turning experiment and simulation. Finite element simulation was adopted to analyze the spatial and temporal distribution of the stress on the cutting tools. The crack initiation and expansion life in the different positions was researched based on the fatigue crack model. The experiment results showed that the fracture area of flank face reduced with the increase in feed rates, while the fracture area and damage depth of rake face both increased. Through the simulation of fatigue crack, it could be inferred that fatigue fractures were caused by coalescence of cracks. When the feed rate was greater than or equal to 0.2 mm, tool failure was mainly manifested as fatigue fracture of the rake face. And the results of fatigue crack propagation simulation well predicted the cutting tool life. A novel research method for tool fatigue failure was provided.

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Study on rotary ultrasonic-assisted drilling of titanium alloys (Ti6Al4V) using 8-facet drill under no cooling condition

Cited by 73 publications

References 27 publications

Investigation on the Effect of a Pre-Center Drill Hole and Tool Material on Thrust Force, Surface Roughness, and Cylindricity in the Drilling of Al7075

Investigation on the Effect of a Pre-Center Drill Hole and Tool Material on Thrust Force, Surface Roughness, and Cylindricity in the Drilling of Al7075

Advances in rotary ultrasonic machining system for hard and brittle materials

Fatigue failure analysis of ceramic tools in intermittent cutting harden steel based on experiments and finite element method

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