Comparative analysis of ultrasonic drilling process using static and rotary tools

Bone drilling is known as one of the most sensitive milling processes in biomedical engineering field. Fracture behavior of this cortical bone during drilling has attracted the attention of many researchers; however, there are still impending concerns such as necrosis, tool breakage, and microcracks due to high cutting forces, torques, and high vibration while drilling. This paper presents a comparative analysis of the cutting forces, torques, and vibration resulted on different bone samples (bovine, porcine, and artificial femur) using a 6dof Robot arm effector with considerations of its stiffness effects. Experiments were conducted on two spindle speeds of 1000 and 1500 rpm with a drill bit diameter of 2.5 mm and 6 mm depth of cut. The results obtained from the specimens were processed and analyzed using MATLAB R2015b and Visio 2000 software; these results were then compared with a prior test using manual and conventional drilling methods. The results obtained show that there is a significant drop in the average values of maximum drilling force for all the bone specimens when the spindle speed changes from 1000 rev/min to 1500 rev/min, with a drop from (20.07 to 12.34 N), approximately 23.85% for bovine, (11.25 to 8.14 N) with 16.03% for porcine, and (5.62 to 3.86 N) with 33.99% for artificial femur. The maximum average values of torque also decrease from 41.2 to 24.2 N·mm (bovine), 37.0 to 21.6 N·mm (porcine), and 13.6 to 6.7 N·mm (artificial femur), respectively. At an increase in the spindle speed, the vibration amplitude on all the bone samples also increases considerably. The variation in drilling force, torque, and vibration in our result also confirm that the stiffness of the robot effector joint has negative effect on the bone precision during drilling process.

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Axiomatic Design in Obtaining a Device for Ultrasonic Machining

MATEC Web of Conferences ◽

10.1051/matecconf/201822301021 ◽

2018 ◽

Vol 223 ◽

pp. 01021

Author(s):

Oana Dodun ◽

Ema Panaite ◽

Petru Duşa ◽

Gheorghe Nagît ◽

Margareta Coteată ◽

...

Keyword(s):

Design Theory ◽

Axiomatic Design ◽

Machining Process ◽

Drilling Process ◽

Relative Pressure ◽

Ultrasonic Machining ◽

Functional Requirements ◽

Analytic Hierarchy ◽

Ultrasonic Drilling ◽

Axiomatic Design Theory

Ultrasonic abrasive cavitational machining is a nonconventional machining method applied to remove surfaces in workpieces made of brittle, hard, or non-conductive materials that cannot be efficiently machined by other classical or nonconventional machining methods. Among the factors that can affect the values of the parameters of technological interest for the ultrasonic machining process, the relative pressure between the ultrasonic tool and the workpiece surface to be machined could be considered. The main objective of the research presented in this paper was to analyze the possibilities of selecting the most convenient solution among many such available solutions to ensure the tool feed motion, when designing a device for achieving an ultrasonic drilling process. At present, this selection could be achieved by means of an optimal selection method. Taking into consideration some functional requirements of the device, the method of analytic hierarchy process and the axiomatic design theory were used to solve some problems met in the design process.

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Experimental Verification of Machining Process of Ultrasonic Drilling

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.516.275 ◽

2012 ◽

Vol 516 ◽

pp. 275-280 ◽

Cited By ~ 3

Author(s):

Hiromi Isobe ◽

Yusuke Uehara ◽

Keisuke Hara ◽

Takashi Onuma ◽

Arata Mihara

Keyword(s):

Stress Distribution ◽

High Speed ◽

Cutting Process ◽

Machining Process ◽

Drilling Process ◽

Distribution Diagram ◽

Heat Resistant Steel ◽

Ultrasonic Drilling ◽

Photoelastic Analysis ◽

Stress Boundary

Drill processing of difficult-to-cut materials such as ceramics, hardened steel, glass and heat-resistant steel is widely required in the industrial world. Furthermore the drilling process becomes more and more difficult in the case of hole diameters less than one millimetre. In order to achieve the requirements for the drilling process, ultrasonically assisted machining is applicable. Ultrasonic vibration assisted machining techniques are suitable for machining difficult-to-cut materials precisely. However, the cutting process of ultrasonic drilling has not been clarified. It is difficult to observe directly the effect of vibration. The aim of this study is to observe the dynamic, instantaneous and micro cutting process. In this report, a high-speed camera with a polarized device, which is appropriately arranged, realized the visualization of the process of ultrasonic drilling based on photoelastic analysis. For conventional drilling, the stress distribution diagram showed that the intensive stress occurred in limited areas under the chisel because the chisel edge of the drill produces large plastic deformation. On the other hand, the ultrasonic drilling produced spread stress distribution and a stress boundary far away from the chisel. The photoelastic analysis showed the explicit difference of drilling processes.

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Developmental and Experimental Study of Rotary Ultrasonic drilling process

International Journal for Research in Applied Science and Engineering Technology ◽

10.22214/ijraset.2021.37795 ◽

2021 ◽

Vol 9 (8) ◽

pp. 2475-2478

Author(s):

Arpit Srivastava

Keyword(s):

Taguchi Method ◽

Material Removal Rate ◽

Material Removal ◽

Removal Rate ◽

Drilling Process ◽

Machining Parameters ◽

Ultrasonic Drilling ◽

Machining Parameter ◽

Rotary Ultrasonic Drilling ◽

Selection Of

Abstract: The proper selection of machining conditions and machining parameter is an important aspect, before going to machine a brittle material by rotary ultrasonic drilling process Because these conditions will determine such important characteristics as; Material removal rate (MRR) and Surface roughness (SR). The purpose of this work is to determine the optimal values of machining parameters of rotary ultrasonic drilling process. The work has been based on the effect of three design factors: Tool feed rate, vibration frequency and grain size of abrasive particle on such characteristic like material removal rate (MRR). This work has been done by means of the technique of design of experiment (DOE), which provides us to perform the above-mentioned analysis with small number of experiments. In this work, a L9 orthogonal array is used to design the experiment. The adequate selection of machining parameters is very important in manufacturing system, because these parameters determine the surface quality and dimensional accuracy of the manufactured part. The optimal setting of the parameters are determined through experiments planned, conducted and analyzed using the Taguchi method. Keywords: RUSM, Material removal rate, Drilling, Taguchi method

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Drilling of Additive Manufactured Poly Lactic Acid Modified byDrilling of Additive Manufactured Poly Lactic Acid Modified by Ultrasonic Vibration Ultrasonic Vibration

10.21203/rs.3.rs-805507/v1 ◽

2021 ◽

Author(s):

Mohammad Baraheni ◽

Mohammad Reza Shabgard ◽

Saeid Amini

Keyword(s):

Lactic Acid ◽

Ultrasonic Vibration ◽

Cutting Tool ◽

Poly Lactic Acid ◽

Drilling Process ◽

Manufacturing Method ◽

Ultrasonic Drilling ◽

Chip Adhesion ◽

The Stability

Abstract Complex geometries can be produced by using additively manufacturing method (AM). As usual, the AM parts have rough surfaces in which post processing operations are needed. One of the useful operations is ultrasonic drilling process. In this process, an additional movement is added to the cutting tool to improve the machinability factors. In this study, poly lactic acid(+) was selected as workpiece where the quality of the holes generated by ultrasonic drilling, were investigated. The examination parameters were delamination, circularity, and cylindricality. As a result, it was shown that UD process could properly improve the examination parameters. It was explained that harmonic movement of drill bit in UD improved the stability of the process by a decrease in cutting forces and chip adhesion. Moreover, a significant reduction was observed in delamination factor by using ultrasonic vibrations.

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Comparative analysis of roller drill bit performance

Proceedings of OilGasScientificResearchProjects Institute SOCAR ◽

10.5510/ogp2021si200536 ◽

2021 ◽

pp. 1-7

Author(s):

A. O. Shigin ◽

◽

D. A. Boreyko ◽

N. D. Tskhadaya ◽

D. Yu. Serikov ◽

...

Keyword(s):

Comparative Analysis ◽

Significant Influence ◽

Operating Conditions ◽

Drilling Process ◽

Drill Bit ◽

Rock Drilling ◽

Drilling Tool ◽

Rock Destruction ◽

Kinematic Characteristics ◽

Efficiency Factors

Currently, roller bits are widely used in rock drilling, which are devices with rotating rollers armed with teeth. There are various approaches in assessing the effectiveness of rock destruction by a roller drilling tool, which can be conditionally divided into structural and technological ones. In addition, all the efficiency factors of the roller bit are related to the correspondence of its characteristics and the drilling process to the properties of the rock it destroys. The article analyzes the operating conditions of the roller bit during drilling of rocks of various hardness. On the example of operation of a two-screw drill bit, the process of power interaction of the toothed weapon with rock is considered depending on various factors, such as the shape and pitch of the teeth, angle of inclination, sharpness of the tooth and others. It is shown that kinematic characteristics of interaction of toothed armament with drilled rock have a significant influence on efficiency of process of face destruction. Keywords: drill bit; drilling tool; destruction; drilling; roller cutter; rock.

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Investigation on thrust force in rotary ultrasonic drilling of CFRP/aluminum stacks

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

10.1177/0954406219877209 ◽

2019 ◽

Vol 234 (2) ◽

pp. 394-404

Author(s):

Song Dong ◽

Wenhe Liao ◽

Kan Zheng ◽

Wenrui Ma

Keyword(s):

Theoretical Model ◽

Thrust Force ◽

Chip Thickness ◽

Machining Process ◽

Aviation Industry ◽

Force Model ◽

Drilling Process ◽

Ultrasonic Drilling ◽

Thrust Forces ◽

Rotary Ultrasonic Drilling

The stacks of carbon fiber-reinforced polymer (CFRP) and aluminum are widely used in aviation industry due to its excellent mechanical and physical properties. Recently, rotary ultrasonic drilling technology which is recognized as a useful machining method has been introduced to machining these stacks. Thrust force influences the machinability directly such as tool wear, cutting temperature, and hole qualities. In this study, a theoretical model of thrust force for rotary ultrasonic drilling of CFRP/aluminum stacks is proposed. Based on the analysis of kinematic characteristics, the axial uncut chip thickness of rotary ultrasonic drilling is presented. Then the whole machining process of stacks is divided into five different states. Forces on cutting edge and chisel edge in different materials are modeled, respectively. After that, the thrust forces of five-state rotary ultrasonic drilling process are achieved by integrating with integral limits analysis in each state. Finally, verification experiments are conducted, and experimental results show that the trends of thrust forces agree well with the thrust force model. Therefore, this theoretical model can be used to evaluate the thrust force in rotary ultrasonic drilling of CFRP/aluminum stacks.

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Effect of Ultrasonic Vibration Drilling on Cutting Stress Distribution

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.523-524.191 ◽

2012 ◽

Vol 523-524 ◽

pp. 191-196 ◽

Cited By ~ 3

Author(s):

Hiromi Isobe ◽

Yusuke Uehara ◽

Keisuke Hara

Keyword(s):

Stress Distribution ◽

Ultrasonic Vibration ◽

High Speed ◽

Side Wall ◽

Drilling Process ◽

Distribution Diagram ◽

Heat Resistant Steel ◽

Ultrasonic Drilling ◽

Photoelastic Analysis ◽

Vibration Drilling

A drill processing for the difficult to cut material such as ceramics, hardened steel, glass and heat-resistant steel is widely requested in the industrial world. Furthermore the drilling process becomes more and more difficult in the case of that the requested hole diameter is less than one millimeter. In order to achieve requirements for drilling process, ultrasonically assisted machining is applicable. Ultrasonic vibration assisted machining techniques are suitable to machine difficult-to-cut materials precisely. The ultrasonic vibration assisted sub-millimeter drilling process reduces the cutting forces and prevents severe wear of tools. However, it is difficult to observe directly the effect of vibration action because the process of ultrasonic drilling is dynamic instantaneous and micro cutting process. In this report, high speed camera with appropriately arranged polarized device realized the visualization of process of ultrasonic drilling based on the photoelastic analysis. For the conventional drilling, the stress distribution diagram showed the intensive stress occurred under the chisel and side wall. On the other hand, the ultrasonic drilling produced lower and stable cutting force and decreased the tool temperature.

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