Experiments and Finite Element Simulation of Ultrasonic Assisted Drilling

In this study, ultrasonic assisted drilling (UAD) is performed to investigate the effect of ultrasonic vibrations on common difficulties existed in conventional drilling (CD). UAD is a promising and advanced technique by which a harmonic movement with high frequency and low amplitude is superimposed on the movement of work material or cutting tool. The study is conducted both experimentally and numerically; at first, a UAD system is designed, manufactured, and carried out on a milling machine and then experimental tests are accomplished. In the following, experimental results are supported by the help of three-dimensional (3D) finite element simulation. Finally, the dependent parameters such as the burr height and cylindricity of the ultrasonically and conventionally drilled workpiece are measured and compared. Briefly, it was proved that the intermittent movement of drill bit in the direction of feed rate results in broken and discontinuous chips by which built-up-edge (BUE) is reduced and hole quality is improved. In addition, the burr height, which is known as unwanted projection of material at the exit surface of pieces, can notably decrease, if UAD is considered.

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Flexural behavior of additively manufactured Ultem 1010: experiment and simulation

Rapid Prototyping Journal ◽

10.1108/rpj-02-2018-0037 ◽

2018 ◽

Vol 24 (6) ◽

pp. 1003-1011 ◽

Cited By ~ 5

Author(s):

Gregory Taylor ◽

Xin Wang ◽

Leah Mason ◽

Ming C. Leu ◽

K. Chandrashekhara ◽

...

Keyword(s):

Finite Element ◽

Finite Element Simulation ◽

Fused Deposition Modeling ◽

Layer Structure ◽

Three Dimensional ◽

Experimental Tests ◽

Flexural Behavior ◽

Content Type ◽

Fused Deposition ◽

Element Simulation

Purpose The purpose of this paper is to study the flexural behavior of additively manufacture Ultem 1010 parts. Fused deposition modeling (FDM) process has become one of most widely used additive manufacturing methods. The process provides the capability of fabricating complicated shapes through the extrusion of plastics onto a print surface in a layer-by-layer structure to build three-dimensional parts. The flexural behavior of FDM parts are critical for the evaluation and optimization of both material and process. Design/methodology/approach This study focuses on the performance of FDM solid and sparse-build Ultem 1010 specimens. Flexure tests (three-point bend) are performed on solid-build coupons with varying build orientation and raster angle. These parameters are investigated through a full-factorial design of experiments (DOE) to determine optimal build parameters. Air gap, raster width and contour width are held constant. A three-dimensional nonlinear finite element model is built to simulate the flexural behavior of the FDM parts. Findings Experimental results include flexure properties such as yield strength and modulus, as well as analysis of the effect of change in build parameters on material properties. The sparse-build FDM parts chosen from the experimental tests are simulated based on this developed model. Thermo-mechanical simulation results show that the finite element simulation and experimental tests are in good agreement. The simulation can be further extended to other complicated FDM parts. Originality/value From the DOE study, sparse-build coupons with specific build parameters are fabricated and tested for the validation of a finite element simulation.

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