Experiments and Finite Element Simulation of Ultrasonic Assisted Drilling

Abstract

In this study, ultrasonic assisted drilling (UAD) is performed to investigate the effect of ultrasonic vibrations on common difficulties existed in conventional drilling (CD). UAD is a promising and advanced technique by which a harmonic movement with high frequency and low amplitude is superimposed on the movement of work material or cutting tool. The study is conducted both experimentally and numerically; at first, a UAD system is designed, manufactured, and carried out on a milling machine and then experimental tests are accomplished. In the following, experimental results are supported by the help of three-dimensional (3D) finite element simulation. Finally, the dependent parameters such as the burr height and cylindricity of the ultrasonically and conventionally drilled workpiece are measured and compared. Briefly, it was proved that the intermittent movement of drill bit in the direction of feed rate results in broken and discontinuous chips by which built-up-edge (BUE) is reduced and hole quality is improved. In addition, the burr height, which is known as unwanted projection of material at the exit surface of pieces, can notably decrease, if UAD is considered.