Skip to main content
SpringerLink
Log in

Comparative study on drilling effect between conventional drilling and ultrasonic-assisted drilling of Ti-6Al-4V/Al2024-T351 laminated material

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

This paper investigates the performance of ultrasonic-assisted drilling (UAD) in machining of Ti-6Al-4V/Al2024-T351 laminated material by using DEFORM-3D finite element method. The effectiveness of two key parameters, frequency and spindle speed, is discussed. The purpose is to explore the effect of UAD on machining performance, to compare it with conventional drilling (CD) and to prove that the UAD technique could achieve better hole quality. To be more specific, the following aspects are taken into account: chip morphology, layer delamination, thrust force, temperature change, and effective stress. The result shows that UAD can produce fragile chips, smaller layer delamination, lower thrust force, larger maximum temperature, and lower effective stress. Both frequency and spindle speed have influence in their own way on machining process.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Botelho EC, Silva RA, Pardini LC, Rezende MC (2006) A review on the development and properties of continuous fiber/epoxy/aluminum hybrid composites for aircraft structures. Mater Res 9(3):247–256

    Article  Google Scholar 

  2. Edward T (2008) Composite materials revolutionize aerospace engineering. Ingenia 36:24–28

    Google Scholar 

  3. Phadniis VA, Farrukh M, Anish R, Silberschmidt VV (2012) Experimental and numerical investigations in conventional and ultrasonically assisted drilling of CFRP laminate. Procedia CIRP 1:455–459

  4. Zhu ZJ, Guo K, Sun J, Li JF, Liu Y, Zheng YH, Chen L (2018) Evaluation of novel tool geometries in dry drilling aluminium 2024-T351/titanium Ti6AL4V stack. J Mater Process Technol 259:270–281

    Article  Google Scholar 

  5. Mishra R, Malik J, Singh I, Davim JP (2010) Neural network approach for estimating the residual tensile strength after drilling in uni-directional glass fiber reinforced plastic laminates. Mater Des 31(6):2790–2795

    Article  Google Scholar 

  6. Mehbudi P, Baghlani V, Akbari J, Bushroa AR, Mardi NA (2013) Applying ultrasonic vibration to decrease drilling-induced delamination in GFRP laminates. SciVerse ScienceDirect 6:577–582

    Google Scholar 

  7. Ni CB, Zhu LD, Liu CF, Yang ZC (2018) Analytical modeling of tool-workpiece contact rate and experimental study in ultrasonic vibration-assisted milling of Ti–6Al–4V. Int J Mech Sci 142–143:97–111

    Article  Google Scholar 

  8. Rawat S, Attia H (2009) Wear mechanisms and tool life management of WC-Co drill during dry high speed drilling of woven carbon fibre composites. Wear 267:1022–1030

    Article  Google Scholar 

  9. Abrao AM, Campos RJ, Faria PE, Davim JP (2008) The effect of cutting tool geometry on thrust force and delamination when drilling glass fibre reinforce plastic composite. Mater Des 29(2):508–513

    Article  Google Scholar 

  10. Rawat S, Attia H (2009) Characterization of the dry high speed drilling process of woven composites using machinability maps approach. J Mater Process Technol 58(1):105–108

    Google Scholar 

  11. Gaitonde VN, Karnik SR, Rubio JC, Correia AE, Abrao AM, Davim JP (2008) Analysis of parametric influence on delamination in high-speed drilling of carbon fiber reinforced plastic composites. J Mater Process Technol 203(1–3):431–438

    Article  Google Scholar 

  12. Karnik SR, Gaitonde VN, Rubio JC, Correia AE, Abrao AM, Davim JP (2008) Delamination analysis in high speed drilling of carbon fiber reinforced plastics (CFRP) using artificial neural network model. Mater Des 29(9):1768–1776

    Article  Google Scholar 

  13. Zhang LB, Wang LJ, Wang X (2003) Study on vibration drilling of fiber reinforced plastics with hybrid variation parameters method. Compos A: Appl Sci Manuf 34(3):237–244

    Article  Google Scholar 

  14. Ramkumar J, Aravindan S, Malhotra SK, Krishamurthy R (2004) An enhancement of the machining performance of GFRP by oscillatory assisted drilling. Int J Adv Manuf Technol 23(3–4):240–244

    Google Scholar 

  15. Wang X, Wang LJ, Tao JP (2004) Investigation on thrust in vibration drilling of fiber-reinforced plastics. J Mater Process Technol 148(2):239–244

    Article  Google Scholar 

  16. Babitsky VI, Astashev VK, Meadows A (2007) Vibration excitation and energy transfer during ultrasonically assisted drilling. J Sound Vib 308(3–5):805–814

    Article  Google Scholar 

  17. Kong C, Wang DZ (2018) Numerical investigation of the performance of elliptical vibration cutting in machining of AISI 1045 steel. Int J Adv Manuf Technol 98(1–4):715–727

    Article  Google Scholar 

  18. Bhatnagar N, Viswanath P, Singh I (2008) Drilling of unidirectional glass fiber reinforced plastics. Experimental and finite element study. Mater Des 29(2):546–553

    Article  Google Scholar 

  19. Phadnis VA, Makhdum F, Roy A, Silberschmidt VV (2013) Drilling in carbon/epoxy composites: experimental investigations and finite element implementation. Compos A: Appl Sci Manuf 47:41–51

    Article  Google Scholar 

  20. Phadnis VA, Makhdum F, Roy A, Silberschmidt VV (2012) Experimental and numerical investigations in conventional and ultrasonically assisted drilling of CFRP laminate. Procedia CIRP 1:455–459

    Article  Google Scholar 

  21. Zhang JH, Zhang QH, Jia ZX, Zhao YG (2014) Combined machining. Chemical industry press, Beijing

    Google Scholar 

  22. Shan CW, Zhang X, Dang J, Yang Y (2018) Rotary ultrasonic drilling of needle-punched carbon/carbon composites: comparisons with conventional twist drilling and high-speed drilling. Int J Adv Manuf Technol 98(1–4):189–200

    Article  Google Scholar 

  23. Li Z, Zhang DY, Jiang XG, Qin W, Geng DX (2017) Study on rotary ultrasonic-assisted drilling of titanium alloys (Ti6Al4V) using 8-facet drill under no cooling condition. Int J Adv Manuf Technol 90(9–12):3249–3264

    Article  Google Scholar 

  24. 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

    Article  Google Scholar 

  25. Paktinat HP, Amini S (2017) Ultrasonic assistance in drilling: FEM analysins and experimental approaches. Int J Adv Manuf Technol 92(5–8):2653–2665

    Article  Google Scholar 

  26. Pujana J, Rivero A, Celaya A, Lo’pez de Lacalle LN (2009) Analysis of ultrasonic-assisted drilling of Ti6Al4V. Int J Mach Tool Manu 49(6):500–508

    Article  Google Scholar 

  27. Li R, Shih AJ (2007) Spiral point drill temperature and stress in high-throughput drilling of titanium. Int J Mach Tools Manuf 47(12–13):2005–2017

    Article  Google Scholar 

  28. Bono M, Ni J (2002) A model for predicting the heat flow into the workpiece in dry drilling. J Manuf Sci Eng 124(4):773–777

    Article  Google Scholar 

  29. Kalidas S, Kapoor SG, DeVor RE (2002) Influence of thermal effects on hole quality in dry drilling, part 1: a thermal model of workpiece temperatures. J Manuf Sci Eng 124(2):258–266

    Article  Google Scholar 

  30. Ueda T, Nozaki R, Hosokawa A (2007) Temperature measurement of cutting edge in drilling-effect of oil mist. CIRP Ann 56(1):93–96

    Article  Google Scholar 

  31. Huang CH, Jan LC, Li R, Shih AJ (2007) A three-dimensional inverse problem in estimating the applied heat flux of a titanium drilling—theoretical and experimental studies. Int J Heat Mass Transf 50(17–18):3265–3277

    Article  MATH  Google Scholar 

  32. Zhang JJ, Wang DZ (2018) Investigations of tangential ultrasonic vibration turning of Ti6Al4V using finite element method. Int J Mater Form 1–11

Download references

Author information

Authors and Affiliations

  1. Shanghai University of Engineering Science, Shanghai, 201620, China

    Lei Wei & Dazhong Wang

Authors
  1. Lei Wei
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Dazhong Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Dazhong Wang.

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

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Wei, L., Wang, D. Comparative study on drilling effect between conventional drilling and ultrasonic-assisted drilling of Ti-6Al-4V/Al2024-T351 laminated material. Int J Adv Manuf Technol 103, 141–152 (2019). https://doi.org/10.1007/s00170-019-03507-6

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-019-03507-6

Keywords

Search

Navigation