To solve the problems consisted of big thrust force and torque that led to the difficulty in drilling operation of machined hole, low tool life, as well as continuous long chip that easily caused the tool entanglement, surface scratches of machined hole, increased frictional effect between the tool, chip and hole wall, and poor removal effect of chip evacuation that easily resulted in the chip jamming and tool jammed after the traditional drilling process of the difficult-to-cut materials like titanium alloys (Ti6Al4V) using the common twist drill, a novel tool (i.e., 8-facet drill) is introduced and the rotary ultrasonic-assisted drilling (RUAD) technology is combined so as to carry out the RUAD experiments of Ti6Al4V. The principles of chip formation in RUAD and common drilling (CD) process are analyzed. And then, the drilling experiments of RUAD and CD of Ti6Al4V based on the 8-facet drill under no cooling condition are performed, which combined with a designed RUAD spindle unit, BV100 vertical machining center platform, measurement system of thrust force and non-contact laser measurement system; meanwhile, the thrust force, torque and chip type in RUAD and CD are studied. The experimental results indicate that compared with the CD of Ti6Al4V, in the RUAD process, the thrust force and torque decreased by 19.07% to 20.09% and 31.66% to 34.3%, respectively, the cutting abilities of chisel edge and major cutting edge are enhanced significantly, the excellent effects of chip breakability and evacuation are obtained, the cutting stability of drilling process is increased, as well as the problems comprised of the big drilling difficulty, low tool life and poor hole quality can be greatly improved.
SHAO Zhenyu
,
LI Zhe
,
ZHANG Deyuan
,
JIANG Xinggang
,
QIN Wei
. Study on the Thrust Force and Chip in Rotary Ultrasonic-assisted Drilling of Titanium Alloys (Ti6Al4V)[J]. Journal of Mechanical Engineering, 2017
, 53(19)
: 66
-72
.
DOI: 10.3901/JME.2017.19.066
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