Mechanical model of thrust force and torque in longitudinal-torsional coupled ultrasonic-assisted drilling of CFRP

Abstract In this study, a special resolution V design and Response surface methodology (RSM) were used to characterize the ultrasonic-assisted drilling (UAD) process of Aluminum 6061. This characterization was done through developing mathematical models to study the effect of ultrasonic and drilling parameters including spindle speed, feed rate and amplitude on thrust force, temperature, chip morphology and power. The tests were done using an industrially hardened non-rotating UAD system mounted in a CNC turning center. The analysis of variance (ANOVA) was used to find significant parameters of thrust force, temperature, chip morphology and power. Then, for all responses, the optimum drilling parameters that provide desired solutions for all responses were obtained. This was followed by out-of-sample testing to verify the accuracy of the developed models. The results of this study showed that in UAD of aluminum, the minimum values of thrust force and chip size were obtained at low spindle speed, low feed rate and high amplitude. The results also showed that amplitude was not a significant parameter affecting the tool temperature and cannot be used to analyze the effect of ultrasonic vibrations on generated heat during UAD. Instead, the interaction of amplitude and feed rate was significant and should be considered in the analysis. Finally, minimum consumed power, specially at higher amplitudes, can be obtained using high spindle speed and low feed rate.

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Mechanical model for predicting thrust force with tool wear effects in drilling of unidirectional CFRP

Composite Structures ◽

10.1016/j.compstruct.2021.113601 ◽

2021 ◽

Vol 262 ◽

pp. 113601

Author(s):

Yu Bai ◽

Zhen-yuan Jia ◽

Rao Fu ◽

Jia-xuan Hao ◽

Fu-ji Wang

Keyword(s):

Tool Wear ◽

Mechanical Model ◽

Thrust Force

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Experimental and Scale-span Numerical Investigations in Conventional and Longitudinal Torsional Coupled Rotary Ultrasonic Assisted Drilling of CFRPs

10.21203/rs.3.rs-537841/v1 ◽

2021 ◽

Author(s):

Yong Liu ◽

Qiannan Li ◽

Zhenchao Qi ◽

Wenliang Chen

Keyword(s):

Thrust Force ◽

Three Dimensional ◽

Fiber Reinforced Polymers ◽

Carbon Fiber Reinforced Polymers ◽

Reinforced Polymers ◽

Delamination Factor ◽

Ultrasonic Assisted ◽

Force Reduction ◽

Drilling Conditions

Abstract Longitudinal torsional coupled rotary ultrasonic assisted drilling (LTC-RUAD) technology is introduced to improve the surface roughness of the hole wall and solve the tear, burr and delamination of carbon fiber reinforced polymers (CFRPs) induced by large thrust force and torque during conventional drilling (CD). An experiment and scale-span numerical investigation of drilling CFRPs was presented for both CD and LTC-RUAD process in this study. A drilling experimental platform using LTC-RUAD was built via a novel independently designed and manufactured LTC-RUAD vibration actuator, while the drilling experiments involving T700S-12K/YP-H26 CFRPs specimens with different process parameters were carried out by adopting the different ultrasonic vibration amplitude (UVA) in the longitudinal and torsional directions. Then, a three-dimensional (3D) scale-span FE simulation model of CD and LTC-RUAD which applied the different UVA using tapered drill-reamer (TDR) are developed to find more details about the effects of machining quality of the holes. Experimental and simulation results revealed that the maximum average thrust force reduction is observed to be as high as 30% under certain drilling conditions, and the maximum average thrust force and the delamination factor of the drilled hole shows a "concave" trend with the increase of the UVA. The quality at the exit of the drilled hole is the best when adopting Sr=2000rpm, Sf=0.01mm/rev, Alon=7.02μm and Ator=9.29μm in LTC-RUAD. The delamination factor is only 0.054. The damage factors are reduced by 69.67% compared with CD.

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Modelling and Optimization for Cutting Forces in Ultrasonic-Assisted Drilling of Soda Glass

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.775.487 ◽

2018 ◽

Vol 775 ◽

pp. 487-492

Author(s):

Abdallah Abdelkawy ◽

Mohab Hossam ◽

Hassan El-Hofy

Keyword(s):

Thrust Force ◽

Spindle Speed ◽

Cutting Fluid ◽

Soda Glass ◽

Ultrasonic Assisted ◽

Abrasive Tools ◽

The Mean ◽

Conventional Drilling ◽

Different Levels ◽

Modelling And Optimization

Ultrasonic-Assisted Drilling (UAD) is a promising technology used for machining difficult-to-cut materials. In this work, an experimental investigation and statistical analysis are used to study the characteristics UAD and conventional drilling (CD) of soda glass using diamond abrasive tools. Statistically designed experiments were conducted using cutting fluid at different levels of tool feed rate, spindle speed, and tool abrasive-concentration. The mean thrust force and moment were considered the main responses. The significant drilling factors and their interactions were identified by modelling the process parameters and the output responses. The statistical models and optimum levels are determined. The ultrasonic application showed a significant effect on reducing the feed forces and drilling moment. Spindle speed is significant factor on thrust force and moment. The models error is less that 9%.

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Study on ultrasonic-assisted drilling of Ti6Al4V using 3-flute drill in the finite element simulation

Proceedings of the Institution of Mechanical Engineers Part C Journal of Mechanical Engineering Science ◽

10.1177/0954406219893001 ◽

2019 ◽

Vol 234 (7) ◽

pp. 1298-1310 ◽

Cited By ~ 1

Author(s):

Peng Wang ◽

Dazhong Wang

Keyword(s):

Finite Element ◽

Tool Wear ◽

Thrust Force ◽

Chip Thickness ◽

Chip Morphology ◽

Drilling Process ◽

Wear Depth ◽

Drill Bit ◽

Drilling Parameters ◽

Ultrasonic Assisted

Continuous chip is one of the major problems during drilling Ti6A14V, and chip breaking is dependent on many factors such as drilling parameters, tool geometries and type of drill bits used. This paper attempts to analyze the effect of various drilling parameters such as feed rate, spindle speed on performance characteristics such as chip morphology, thrust force, temperature, and tool wear in conventional drilling and ultrasonic-assisted drilling of Ti6A14V using twist drill bit and 3-flute drill bit in order to optimize the chip breakability of Ti6A14V. The twist and 3-flute drill bit are utilized to establish the finite element models to simulate the drilling process with Lagrangian approach in DEFORM-3D software. The results of the simulations not only reveal obvious varying regular pattern of thrust force, temperature, tool wear depth, chip thickness and damage with the increasing of feed rates, spindle speeds, which confirm the capability and advantage of finite element model of the drilling process, but also provide a more profound knowledge about the drilling mechanism including the effect of 3-flute drill bit in ultrasonic-assisted drilling on chip breakability and tool wear.

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Comparison of Thrust Force in Ultrasonic Assisted Drilling and Conventional Drilling of Aluminum Alloy

Materials Science Forum ◽

10.4028/www.scientific.net/msf.861.38 ◽

2016 ◽

Vol 861 ◽

pp. 38-43 ◽

Cited By ~ 5

Author(s):

Xiao Feng Li ◽

Zhi Gang Dong ◽

Ren Ke Kang ◽

Yi Dan Wang ◽

Jin Ting Liu ◽

...

Keyword(s):

Aluminum Alloy ◽

Vibration Amplitude ◽

Complex Shape ◽

Thrust Force ◽

Drill Bit ◽

Twist Drill ◽

Drilling Force ◽

Drilling Parameters ◽

Ultrasonic Assisted ◽

Conventional Drilling

The origin of drilling force in drilling with twist drill is quite complicated owning to the complex shape of the drill bit cutting edges. In this paper, the drilling experiments both with and without the ultrasonic were designed and conducted on aluminum alloy with pre-drilled hole. The drilling force was tested and the different effects between the cutting edges of the twist drill on the drilling force were analyzed under various drilling parameters including the spindle speed, feed rate and vibration amplitude. The drilling force of conventional drilling (CD) and ultrasonic assisted drilling (UAD) was characterized and the roles of the ultrasonic vibration in drilling were discussed.

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