Study Of Machanism And Craft Of Ultrasonic Vibration Aided Drilling Ti Alloys

As the non-traditional machining method, ultrasonic vibration aided drilling (UVAD) is a new manner of drilling based on the theory of vibration and cutting, which is a branch of vibration cutting. UVAD, which has changed the cutting mechanism of traditional drilling, has irreplaceable advantage on small-hole and deep-hole machining. Amounts of theories and experiments indicated chip-broken and chip-removal effect, machining quality, tool life and so on has greatly improved.Maths model and FEA model of conventional drilling and UVAD was established; ultrasonic vibration can reduce firction force, cutting force and torque through theory analysis and simulation. Compared conventional drilling, average axial force and torgue of manufacturing AISI-Al2024,AISI-1045 by UVAD reduced 33%,17% and 33%,26%, and maximum axial force and torgue of manufacturing Ti6Al4V reduced 50%,44%. It is proved by simulation and experiments that the heat of the tool generated by ultrasonic vibration, which can not quickly diffused, lead to the high temperature of the tool by UVAD.Ultrasonic vibration aided drilling system was established. Through extensive research, the piezoelectric ultrasonic transducer and generator made in the America Company DUKANE are selected. The tool is designed based on theory and software ANSYS analysis. The system including tool rest was established and can feed on the conventional machine.Conventional drilling and UVAD experiments was carried on the materials of AISI-Al2024,AISI-1045,Ti6Al4Mo. Chips of UVAD were thin and broken into pieces, in order. The helicity of big chip was high and the thickness was small; the surface of workpiece of Ti6Al4Mo manufactured by UVAD was shining and average of roughness was 1.3μm, compared to the 2.9μm of conventional drilling and the texture was clear.It is thought while machining high-hardness and hard-to-machine material, using the experiment system and cutting manner of UVAD can not only enhance chip broken and removal, and prolong the tool life, but also improve cutting quality, which is fit for high-hardness and hard-to-machine materials. But the disadvantage of UVAD was that manufacturing temperature was high and was not so stable under complicated working condition.