Abstract
In the drilling process of difficult-to-cut materials, conventional drilling has resulted in various problems such as high drilling temperature and poor machining quality. Low-frequency vibration-assisted drilling has great potential in overcoming these problems since broken chips are generated. In this paper, a low-frequency vibration-assisted drilling device is developed by using a novel ring flexure hinge as the elastic recovery mechanism. Firstly, based on the theory of elastic mechanics and mechanical vibration, the deflection of ring flexure hinge is designed theoretically, and the influence of its structural parameters on its deflection is analyzed. Then, the correctness of theoretical design is further verified by static and dynamic simulation and stiffness test. Finally, the vibration performance of the device is tested under no-load condition, and actual drilling test is conducted to verify the drilling performance. The results show that the device could realize the axial low-frequency vibration with constant frequency-to-rotation ratio and amplitude stepless adjustment and present good working stability under no-load and load conditions. In the actual drilling test of titanium alloy and carbon fiber–reinforced plastic (CFRP)/titanium alloy laminated structure, the device under appropriate processing parameters breaks titanium alloy chip into small pieces and reduces drilling temperature by 44% and inhibits secondary damage of CFRP. It provides the reference and guidance for the development of LFVAD device in presented work.
Highlights
Difficult-to-cut materials such as titanium alloy, high temperature alloy and composite materials have a great prospect in aerospace and aircraft manufacturing
The vibration performance of the device is tested under no-load condition, and the actual drilling test of titanium alloy and carbon fiber reinforced plastic (CFRP)/ titanium alloy laminated structure is conducted to verify the drilling performance
Compared with conventional drilling (CD) (A=0 μm), the maximum temperature of low-frequency vibration-assisted drilling (LFVAD) with amplitude of 20 μm is reduced by about 44%
Summary
Difficult-to-cut materials such as titanium alloy, high temperature alloy and composite materials have a great prospect in aerospace and aircraft manufacturing. The machining difficulties of the difficult-to-cut materials have been reported, such as delamination damage during drilling of CFRP and CFRP/titanium alloy stacked materials [3], chip evacuation during drilling, and low thermal conductivity combined with a high chemical affinity of titanium alloys [4, 5]. These machinability problems lead to high machining temperature, short tool life and poor machining quality. The vibration performance of the device is tested under no-load condition, and the actual drilling test of titanium alloy and CFRP/ titanium alloy laminated structure is conducted to verify the drilling performance
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