Abstract
Regarding drilling, ultrasonic-assistance enables various potentials such as less tool wear, enhanced chip breaking and burr reduction. Although there are many technological studies verifying these advantages, no theory for process behaviour, design and parameter evaluation is available. Thus, this paper presents a kinematic analysis of the interaction between tool and workpiece to contribute to overall process understanding. Specific process scenarios are classified and characteristic parameters for the evaluation and design of ultrasonic-assisted drilling are determined. In addition, experimental investigations based on the developed process model are carried out analysing chip shape, bore surface and process stability acquired by acoustic measurements. The kinematic analysis shows the classification of ultrasonic-assisted drilling according to continuous and intermitted cutting conditions. In addition, the superposition of ultrasonic vibrations causes a modulation of uncut chip thickness related to the ratio of ultrasonic frequency and spindle speed. In general, experimental results show that ultrasonic-assisted drilling is leading to shorter chips. While using parameters for intermitted cutting conditions needle chips occur. At the same time, intermitted cutting conditions induce process instabilities identified using the acoustic measurement approach.
Highlights
Due to increasing demands on manufacturing processes aiming for higher resource and energy efficiency, minimization of production costs and time combined with unchanged or even better quality, it is necessary to shift limits of conventional machining processes
This paper aims at generating a better understanding of the behaviour of ultrasonic-assisted drilling (UAD) with defined cutting edge using a resonant system to generate vibrations in feed direction
The values are calculated based on the ultrasonic frequency acquired from the generator voltage during the drilling tests
Summary
Due to increasing demands on manufacturing processes aiming for higher resource and energy efficiency, minimization of production costs and time combined with unchanged or even better quality, it is necessary to shift limits of conventional machining processes. The approach of hybrid machining is a suitable method that enables high-performance cutting to address these challenges [1]. In this context, vibrationassisted machining (VAM) uses additional energy in terms of vibrations to realize a hybrid process [2]. UAM provides lower process forces, increased tool life and process stability, better chip breaking, avoidance Since the early beginnings in the 1960’s [3, 4], ultrasonic assistance was studied covering a wide range of machining processes [2, 5].
Sign-in/Register to view highlights & summary Sign-in/Register to access full text options 
Free) 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a call
