Study on tool wear in longitudinal-torsional composite ultrasonic vibration–assisted drilling of Ti-6Al-4V alloy

Abstract

Severe tool wear is always considered as a main negative result in the process of drilling Ti-6Al-4V alloy. Although the idea of employing one-dimensional longitudinal ultrasonic vibration in the drilling process to reduce tool wear has been proposed for many years, studies on longitudinal-torsional composite ultrasonic vibration–assisted drilling (LT-UAD) are seldom reported. LT-UAD is a hybrid machining process in which high-frequency and low-amplitude vibrations are superimposed simultaneously on the rotational direction and the axial direction of the drilling bit respectively. In this study, a hollow vibration converter with thread grooves is presented for LT-UAD purpose. Based on an in-depth kinematic analysis, a condition for separating the tool from the workpiece is derived, indicating that a lower feed rate, a lower spindle speed, and a higher amplitude are more advantageous. Machining experiments are performed, wherein good agreement is found between the experimental and theoretical results. The results show that LT-UAD has obvious advantages over longitudinal ultrasonic vibration–assisted drilling and conventional drilling in reducing tool wear. Additionally, the influences of the vibration amplitude, spindle speed, and feed rate on the flank wear width are analyzed, revealing the influences of the three factors in descending order are feed rate, amplitude, and spindle speed. The optimum machining parameters are obtained as 23 μm of amplitude, 385 r/min of spindle speed, and 0.06 mm/r of feed rate. Furthermore, a reliable regression model of flank wear width is established based on response surface methodology. With this prediction model, the flank wear width of drill bit under different machining parameters can be accurately predicted.

This is a preview of subscription content, access via your institution.

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14

Availability of data and materials

All data used in the manuscript are available as submitted.

Code availability

Not applicable.

References

  1. 1.

    Ma J, Andrus P, Condoor S, Lei S (2015) Numerical investigation of effects of cutting conditions and cooling schemes on tool performance in up milling of Ti-6AL-4V alloy. Int J Adv Manuf Technol 78(1-4):361–383

    Article  Google Scholar 

  2. 2.

    Manjaiah M, Narendranath S, Basavarajappa S (2014) A review on machining of titanium based alloys using EDM and WEDM. Rev Adv Mater Sci 36(2):89–111

    Google Scholar 

  3. 3.

    de Lacalle LNL, Rivero A, Lamikiz A (2009) Mechanistic model for drills with double point-angle edges. Int J Adv Manuf Technol 40(5-6):447–457

    Article  Google Scholar 

  4. 4.

    Parida AK (2018) Simulation and experimental investigation of drilling of Ti-6Al-4V alloy. Int J Lightweight Mater Manuf 1(3):197–205

    Google Scholar 

  5. 5.

    Yi S, Li G, Ding S, Mo J (2017) Performance and mechanisms of graphene oxide suspended cutting fluid in the drilling of titanium alloy Ti-6Al-4V. J Manuf Process 182-193

  6. 6.

    Trivedi DB, Kumar A, Joshi SS (2018) Surface integrity analysis in heat sink-based dry drilling of titanium alloy. Mater Today Proc 5(9):19529–19538

    Article  Google Scholar 

  7. 7.

    Trivedi DB, Kumar A, Joshi SS (2018) Drilling of titanium alloy using heat sink-based ice water cooling. Procedia Manuf 26:633–644

    Article  Google Scholar 

  8. 8.

    Rodríguez-Barrero S, Fernández-Larrinoa J, Azkona I et al (2014) Enhanced performance of nanostructured coatings for drilling by droplet elimination. Mater Manuf Process 31(5):593–602

    Article  Google Scholar 

  9. 9.

    Chatterjee S, Mahapatra SS, Abhishek K (2016) Simulation and optimization of machining parameters in drilling of titanium alloys. Simul Model Pract Theory 62:31–48

    Article  Google Scholar 

  10. 10.

    Muhamad Nasir M, Safian S (2014) Effect of drill point angle on surface integrity when drilling titanium alloy. Adv Mater Res 845:966–970

    Google Scholar 

  11. 11.

    Yang H, Ding W, Chen Y, Laporte S, Xu J, Fu Y (2019) Drilling force model for forced low frequency vibration assisted drilling of Ti-6Al-4V titanium alloy. Int J Mach Tool Manu 146:103438

    Article  Google Scholar 

  12. 12.

    Suárez A, Veiga F, de Lacalle LNL, Polvorosa R, Lutze S, Wretland A (2016) Effects of ultrasonics-assisted face milling on surface integrity and fatigue life of Ni-Alloy 718. J Mater Eng Perform 25(11):5076–5086

    Article  Google Scholar 

  13. 13.

    Xu Y, Gao F, Zou P, Zhang Q, Fan F (2020) Theoretical and experimental investigations of surface roughness, surface topography, and chip shape in ultrasonic vibration-assisted turning of Inconel 718. J Mech Sci Technol 34(9):3791–3806

    Article  Google Scholar 

  14. 14.

    Tian Y, Zou P, Yang X, Kang D (2020) Study on chip morphology and surface roughness in ultrasonically assisted drilling of 304 stainless steel. Int J Adv Manuf Technol 108:2079–2090

    Article  Google Scholar 

  15. 15.

    Xu Y, Wan Z, Zou P, Huang W, Zhang G (2020) Experimental study on cutting force in ultrasonic vibration-assisted turning of 304 austenitic stainless steel. P i Mech Eng B J Eng 0954405420957127

  16. 16.

    Zhang DY, Feng XJ, Wang LJ, Chen DC (1994) Study on the drill skidding motion in ultrasonic vibration microdrilling. Int J Mach Tool Manu 34(6):847–857

    Article  Google Scholar 

  17. 17.

    Zhang LB, Wang LJ, Liu XY, Zhao HW, Wang X, Luo HY (2001) Mechanical model for predicting thrust and torque in vibration drilling fibre-reinforced composite materials. Int J Mach Tool Manu 41(5):641–657

    Article  Google Scholar 

  18. 18.

    Azarhoushang B, Akbari J (2007) Ultrasonic-assisted drilling of Inconel 738-lc. Int J Mach Tool Manu 47(7):1027–1033

    Article  Google Scholar 

  19. 19.

    Barani A, Amini S, Paktinat H, Fadaei Tehrani A (2014) Built-up edge investigation in vibration drilling of al2024-t6. Ultrasonics 54(5):1300–1310

    Article  Google Scholar 

  20. 20.

    Baghlani V, Mehbudi P, Akbari J, Nezhad EZ, Sarhan AAD, Hamouda AMS (2016) An optimization technique on ultrasonic and cutting parameters for drilling and deep drilling of nickel-based high-strength Inconel 738lc superalloy with deeper and higher hole quality. Int J Adv Manuf Technol 82(5-8):877–888

    Article  Google Scholar 

  21. 21.

    Lotfi M, Amini S (2017) Experimental and numerical study of ultrasonically-assisted drilling. Ultrasonics 75:185–193

    Article  Google Scholar 

  22. 22.

    Liang W, Xu J, Ren W, Liu Q, Yu H (2019) Study on the influence of tool point angle on ultrasonic vibration–assisted drilling of titanium alloy. Int J Adv Manuf Technol 1–14

  23. 23.

    Chen S, Zou P, Tian Y, Duan J, Wang W (2019) Study on modal analysis and chip breaking mechanism of Inconel 718 by ultrasonic vibration-assisted drilling. Int J Adv Manuf Technol 105(1-4):177–191

    Article  Google Scholar 

  24. 24.

    Chen S, Zou P, Wu H, Kang D, Wang W (2019) Mechanism of chip formation in ultrasonic vibration drilling and experimental research. P i Mech Eng C-J Mec 233(15):5214–5226

    Article  Google Scholar 

  25. 25.

    Celaya A, Lacalle LNLD, Campa FJ, Lamikiz A (2010) Ultrasonic assisted turning of mild steels. Int J Mater Prod Technol 37(1-2):60–70

    Article  Google Scholar 

  26. 26.

    Haidong ZHAO, Shuguang L, Ping ZOU, Di K (2017) Process modeling study of the ultrasonic elliptical vibration cutting of Inconel 718. Int J Adv Manuf Technol 92(5-8):2055–2068

    Article  Google Scholar 

  27. 27.

    Haidong Z, Ping Z, Wenbin M, Zhongming Z (2016) A study on ultrasonic elliptical vibration cutting of Inconel 718. Shock Vib 2016:1–11

    Article  Google Scholar 

  28. 28.

    Liu J, Jiang X, Han X, Zhang D (2019) Influence of parameter matching on performance of high-speed rotary ultrasonic elliptical vibration-assisted machining for side milling of titanium alloys. Int J Adv Manuf Technol 101(5-8):1333–1348

    Article  Google Scholar 

  29. 29.

    Liu J, Jiang X, Han X, Gao Z, Zhang D (2019) Effects of rotary ultrasonic elliptical machining for side milling on the surface integrity of Ti-6Al-4V. Int J Adv Manuf Technol 101(5-8):1451–1465

    Article  Google Scholar 

  30. 30.

    Liu S, Shan X, Cao W, Yang Y, Xie T (2017) A longitudinal-torsional composite ultrasonic vibrator with thread grooves. Ceram Int 43:S214–S220

    Article  Google Scholar 

  31. 31.

    Qi A, Friend J, Yeo L (2007) An analytical model for a twisted beam piezoelectric ultrasonic micromotor. 5th Australasian Congress on Applied Mechanics 325–330

  32. 32.

    Yang C, Shan X, Xie T (2015) A new piezoelectric ceramic longitudinal–torsional composite ultrasonic vibrator for wire drawing. Ceram Int 41:S625–S630

    Article  Google Scholar 

  33. 33.

    Al-Budairi H, Lucas M, Harkness P (2013) A design approach for longitudinal–torsional ultrasonic transducers. Sensor Actuators A Phys 198:99–106

    Article  Google Scholar 

  34. 34.

    Thakre AA, Soni S (2016) Modeling of burr size in drilling of aluminum silicon carbide composites using response surface methodology. Eng Sci Technol 19(3):1199–1205

    Google Scholar 

  35. 35.

    Chelladurai SJS, Murugan K, Ray AP, Upadhyaya M, Narasimharaj V, Gnanasekaran S (2020) Optimization of process parameters using response surface methodology: a review. Materials Today: Proceedings. https://doi.org/10.1016/j.matpr.2020.06.466

Download references

Funding

The authors are grateful for the financial support received from the National Natural Science Foundation of China (Grant No. 51875097).

Author information

Affiliations

Authors

Corresponding author

Correspondence to Ping Zou.

Ethics declarations

Ethical approval

Not applicable.

Consent to participate

Not applicable.

Consent to publish

Not applicable.

Competing interests

The Authors wish to declare that there are no known competing interests related to this publication.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and Permissions

About this article

Verify currency and authenticity via CrossMark

Cite this article

Tian, Y., Zou, P., Kang, D. et al. Study on tool wear in longitudinal-torsional composite ultrasonic vibration–assisted drilling of Ti-6Al-4V alloy. Int J Adv Manuf Technol (2021). https://doi.org/10.1007/s00170-021-06759-3

Download citation

Keywords

  • Ti-6Al-4V alloy
  • Longitudinal-torsional composite vibration
  • Ultrasonic vibration assisted drilling
  • Tool wear
  • Machining parameter optimization
  • Prediction model