Abstract
The DD6 nickel-based superalloy exhibits remarkably high temperature properties; therefore, it is employed as a crucial structural material in the aviation industry. Nevertheless, this material is difficult to process. Ultrasonic-assisted drilling (UAD) combines the characteristics of vibration processing technology and conventional drilling technology, significantly improving the machinability of difficult-to-machine materials. Thus, UAD experiments were performed on micro-hole machining of DD6 superalloy in this study. The effects of amplitude, frequency, spindle speed, and feed rate on thrust force, machining quality, and drill bit wear were studied; thereafter, a comparison was drawn between these effects and those of conventional drilling (CD). The experimental results reveal that the thrust force decreases with an increase in spindle speed or a decrease in feed rate for both UAD and CD. UAD can significantly reduce the thrust force. With the same processing parameters, the greater the amplitude, the greater the reduction of the thrust force. The surface roughness of the hole wall produced by UAD is lower than that of CD. Compared with CD, UAD reduces the burr height, improves machining accuracy, and reduces drill bit wear.
Similar content being viewed by others
References
Zhu HN, Qi XX (2011) Development of machining technology gas holes on turbine blades. Aeronaut Manuf Technol 13:71–74
Qi HY, Wang YM, Yang XG et al (2008) Thermal fatigue of atmospheric plasma sprayed thermal barrier coating. Fail Anal Prevent 1:15–18
Liu J (1995) Drilling technique of aeroengine cooling hole. Aeroengine 2:31–36
He F, Cheng Y (2007) Femtosecond laser micromachining: frontier in laser precision micromachining. Chin J Lasers 34(5):595–622
Guo WY, Wang MC, Zhang XB (2003) Recast layer formed by laser drilling of Ni-based superalloys and progress on its control. Laser J 24(4):1–3
Tan C (2014) Research on processing technology and surface quality of metal microholes machined by femtosecond laser. Dissertation, Zhongnan University, China
Wang ML, Yang LJ, Zhang S et al (2018) Experimental investigation on the spiral trepanning of K24 superalloy with femtosecond laser. Opt Laser Technol 101:284–290
Thomas PNH, Babitsky VI (2007) Experiments and simulations on ultrasonically assisted drilling. J Sound Vib 308(3/5):815–830
Neugebauer R, Stoll A (2004) Ultrasonic application in drilling. J Mater Process Technol 149(1/3):633–639
Zhang DY, Feng XJ, Wang LJ et al (1994) Study on the drill skidding motion in ultrasonic vibration microdrilling. Int J Mach Tools Manuf 34(6):847–857
Alam K, Mitrofanov AV, Silberschmidt VV (2011) Experimental investigations of forces and torque in conventional and ultrasonically-assisted drilling of cortical bone. Med Eng Phys 33(2):234–239
Alam K, Mitrofanov AV, Silberschmidt VV (2009) Measurements of surface roughness in conventional and ultrasonically assisted bone drilling. Am J Biomed Sci 1(4):312–320
Takemaya H, Kato S (1991) Burrless drilling by means of ultrasonic vibration. CIRP Ann Manuf Technol 40(1):83–86
Chang SSF, Bone GM (2005) Burr size reduction in drilling by ultrasonic assistance. Robot Comput Integr Manuf 21(4/5):442–450
Aziz M, Ohnishi O, Onikura H (2012) Novel micro deep drilling using micro long flat drill with ultrasonic vibration. Precis Eng J Int Soc Precis Eng Nanotechnol 36(1):168–174
Chu NH, Nguyen VD, Ngo QH (2019) Machinability enhancements of ultrasonic-assisted deep drilling of aluminum alloys. Mach Sci Technol 24(1):112–135
Chang SSF, Bone GM (2010) Burr height model for vibration assisted drilling of aluminum 6061-T6. Precis Eng J Int Soc Precis Eng Nanotechnol 34(3):369–375
Babitsky VI, Astashev VK, Meadows A (2007) Vibration excitation and energy transfer during ultrasonically assisted drilling. J Sound Vib 308(3/5):805–814
Heisel U, Wallaschek J, Eisseler R et al (2008) Ultrasonic deep hole drilling in electrolytic copper ECu 57. CIRP Ann Manuf Technol 57(1):53–56
Sanda A, Arriola I, Navas VG et al (2016) Ultrasonically assisted drilling of carbon fibre reinforced plastics and Ti6Al4V. J Manuf Process 22:169–176
Makhdum F, Jennings LT, Roy A et al (2012) Cutting forces in ultrasonically assisted drilling of carbon fibre-reinforced plastics. J Phys: Conf Ser 382(1):012019
Phadnis VA, Makhdum F, Roy A et al (2012) Experimental and numerical investigations in conventional and ultrasonically assisted drilling of CFRP laminate. Proc CIRP 1:455–459
Gupta A, Barnes S, McEwen I et al (2014) Study of cutting speed variation in the ultrasonic assisted drilling of carbon fibre composites. In: ASME 2014 mechanical engineering congress and exposition V02BT02A038
Makhdum F, Norddin DNP, Roy A et al (2012) Ultrasonically assisted drilling of carbon fibre reinforced plastics. Solid State Phenom 188:170–175
Makhdum F, Phadnis VA, Roy A et al (2014) Effect of ultrasonically-assisted drilling on carbon-fibre-reinforced plastics. J Sound Vib 333(23):5939–5952
Yang HJ, Ding WF, Chen Y et al (2019) Drilling force model for forced low frequency vibration assisted drilling of Ti-6Al-4V titanium alloy. Int J Mach Tools Manuf 146:103438
Paktinat H, Amini S (2017) Ultrasonic assistance in drilling: FEM analysis and experimental approaches. Int J Adv Manuf Technol 92(5/8):2653–2665
Lotfi M, Amini S (2017) Experimental and numerical study of ultrasonically-assisted drilling. Ultrasonics 75:185–193
Liao YS, Chen YC, Lin HM (2007) Feasibility study of the ultrasonic vibration assisted drilling of Inconel superalloy. Int J Mach Tools Manuf 47(12/13):1988–1996
Baghlani V, Mehbudi P, Akbari J et al (2013) Ultrasonic assisted deep drilling of Inconel 738LC superalloy. Proc CIRP 6:571–576
Azarhoushang B, Akbari J (2007) Ultrasonic-assisted drilling of Inconel 738-LC. Int J Mach Tools Manuf 47(7/8):1027–1033
Chen S, Zou P, Tian YJ et al (2019) Study on modal analysis and chip breaking mechanism of Inconel 718 by ultrasonic vibration-assisted drilling. Int J Adv Manuf Technol 105:177–191
Acknowledgements
This study was supported by the National Scholastic Athletics Foundation (NSAF) (Grant No. U1830122) and the National Natural Science Foundation of China (Grant No. 51775443).
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Zhu, XX., Wang, WH., Jiang, RS. et al. Research on ultrasonic-assisted drilling in micro-hole machining of the DD6 superalloy. Adv. Manuf. 8, 405–417 (2020). https://doi.org/10.1007/s40436-020-00301-6
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s40436-020-00301-6