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Thrust force model for ultrasonic-assisted micro drilling of DD6 superalloy

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Abstract

As a typical refractory material, the DD6 nickel-based single-crystal superalloy has important applications in the aviation industry. Ultrasonic-assisted drilling is an advanced machining method that significantly improves machining of refractory materials. The drilling thrust force influences the hole surface quality, burr height, and bit wear. Therefore, it is necessary to predict the thrust force during ultrasonic-assisted drilling. However, there are few reports on the modeling of the thrust force in the ultrasonic-assisted drilling of micro-holes. A thrust force prediction model for ultrasonic-assisted micro-drilling is proposed in this study. Based on the basic cutting principle, the dynamic cutting speed, dynamic cutting thickness, and acoustic softening effect caused by ultrasonic vibrations are factored into this model. Through model calibration, the specific friction force and specific normal force coefficients were determined. The model was verified through ultrasonic-assisted drilling experiments conducted at different feed rates, spindle speeds, frequencies, and amplitudes. The maximum and minimum errors of the average thrust force were 10.5% and 2.3%, respectively. This model accurately predicts the thrust force based on the parameters used for ultrasonic-assisted micro-hole drilling and can assist in the analysis and modeling of DD6 superalloy processing.

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Abbreviations

f z :

Feed per revolution (mm/r)

N :

Spindle speed (r/s)

t :

Time (s)

f :

Vibration frequency (Hz)

A :

Amplitude (μm)

t a :

Axial uncut chip thickness (mm)

t i :

Instantaneous uncut chip thickness (mm)

ϕ :

Half point angle (°)

h :

Helix angle (°)

F n :

Normal force (N)

F f :

Friction force (N)

A c :

Uncut chip area (mm2)

K n :

Specific normal force (N/mm2)

K f :

Specific friction force (N/mm2)

v c :

Cutting speed (mm/s)

2w :

Web thickness (mm)

α n :

Normal rake angle (°)

i :

Inclination angle (°)

l chi :

Length of the chisel edge (mm)

F zCD :

Thrust force measured in conventional drilling (N)

η c :

Chip flow angle (°)

φ :

Chisel edge angle (°)

dF mcut :

Elemental cutting force in main cutting edge (N)

dF mthu :

Elemental oblique cutting thrust force in main cutting edge (N)

dF mlat :

Elemental lateral force in main cutting edge (N)

dF ccut :

Elemental cutting force in chisel edge (N)

dF cthu :

Elemental thrust force in chisel edge (N)

ω :

Circular frequency (rad/s)

s :

Wave velocity

E :

Young's modulus

F r c cin :

Reduction in indentation force (N)

k :

Acoustic softening coefficient of material

F ccin :

Indentation force in conventional drilling (N)

F zTotal :

Total thrust force in ultrasonic-assisted drilling (N)

F cin :

Indentation force in ultrasonic-assisted drilling (N)

F(t):

Instantaneous feed rate (mm/s)

l chi :

Length of the chisel edge (mm)

F zUAD :

Thrust force measured in ultrasonic assisted drilling (N)

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Acknowledgements

This work was sponsored by the National Natural Science Foundation of China (Grant No. 51775443), the National Science and Technology Major Project (Grant No. 2017-VII-0015-0111), and China Postdoctoral Science Foundation (Grant No. 2020M683569).

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Authors and Affiliations

  1. Key Laboratory of High Performance Manufacturing for Aero Engine, Ministry of Industry and Information Technology, School of Mechanical Engineering, Northwestern Polytechnical University, **’an, 710072, People’s Republic of China

    **ao-**ang Zhu, Wen-Hu Wang, Yi-Feng **ong & **ao-Fen Liu

  2. Engineering Research Center of Advanced Manufacturing Technology for Aero Engine, Ministry of Education, School of Mechanical Engineering, Northwestern Polytechnical University, **’an, 710072, People’s Republic of China

    **ao-**ang Zhu, Wen-Hu Wang, Yi-Feng **ong & **ao-Fen Liu

  3. School of Aeronautics and Astronautics, Sichuan University, Chengdu, 610065, People’s Republic of China

    Rui-Song Jiang

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  1. **ao-**ang Zhu
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Correspondence to Yi-Feng **ong.

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Zhu, XX., Wang, WH., Jiang, RS. et al. Thrust force model for ultrasonic-assisted micro drilling of DD6 superalloy. Adv. Manuf. 10, 313–325 (2022). https://doi.org/10.1007/s40436-021-00381-y

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  • DOI: https://doi.org/10.1007/s40436-021-00381-y

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