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

doi:10.1007/s40436-021-00381-y

Advances in Manufacturing ›› 2022, Vol. 10 ›› Issue (2): 313-325.doi: 10.1007/s40436-021-00381-y

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

Xiao-Xiang Zhu^1,2, Wen-Hu Wang^1,2, Rui-Song Jiang³, Yi-Feng Xiong^1,2, Xiao-Fen Liu^1,2

1. Key Laboratory of High Performance Manufacturing for Aero Engine, Ministry of Industry and Information Technology, School of Mechanical Engineering, Northwestern Polytechnical University, Xi’an 710072, People’s Republic of China;
2. Engineering Research Center of Advanced Manufacturing Technology for Aero Engine, Ministry of Education, School of Mechanical Engineering, Northwestern Polytechnical University, Xi’an 710072, People’s Republic of China;
3. School of Aeronautics and Astronautics, Sichuan University, Chengdu 610065, People’s Republic of China

收稿日期:2021-03-08 修回日期:2021-05-19 发布日期:2022-06-11
通讯作者: Yi-Feng Xiong E-mail:xiongyf@nwpu.edu.cn
基金资助:
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).

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

Xiao-Xiang Zhu^1,2, Wen-Hu Wang^1,2, Rui-Song Jiang³, Yi-Feng Xiong^1,2, Xiao-Fen Liu^1,2

1. Key Laboratory of High Performance Manufacturing for Aero Engine, Ministry of Industry and Information Technology, School of Mechanical Engineering, Northwestern Polytechnical University, Xi’an 710072, People’s Republic of China;
2. Engineering Research Center of Advanced Manufacturing Technology for Aero Engine, Ministry of Education, School of Mechanical Engineering, Northwestern Polytechnical University, Xi’an 710072, People’s Republic of China;
3. School of Aeronautics and Astronautics, Sichuan University, Chengdu 610065, People’s Republic of China

Received:2021-03-08 Revised:2021-05-19 Published:2022-06-11
Contact: Yi-Feng Xiong E-mail:xiongyf@nwpu.edu.cn
Supported by:
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).

摘要/Abstract

摘要： 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.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-021-00381-y

关键词: Ultrasonic-assisted drilling, DD6 superalloy, Thrust force model, Dynamic cutting thickness, Acoustic softening effect

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.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-021-00381-y

Key words: Ultrasonic-assisted drilling, DD6 superalloy, Thrust force model, Dynamic cutting thickness, Acoustic softening effect

Xiao-Xiang Zhu, Wen-Hu Wang, Rui-Song Jiang, Yi-Feng Xiong, Xiao-Fen Liu. Thrust force model for ultrasonic-assisted micro drilling of DD6 superalloy[J]. Advances in Manufacturing, 2022, 10(2): 313-325.

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

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

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