Numerical simulation and experimental study for ultrasonic vibration-assisted drilling of SiCp/AL6063

Xu Ji; Fan Bai; Jiang Jiang; Hongge Fu; Qingjie Sun; Weiyu Zhu; Xu Ji; Fan Bai; Jiang Jiang; Hongge Fu; Qingjie Sun; Weiyu Zhu

doi:10.3934/mbe.2023124

Mathematical Biosciences and Engineering

2023, Volume 20, Issue 2: 2651-2668. doi: 10.3934/mbe.2023124

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Research article

Numerical simulation and experimental study for ultrasonic vibration-assisted drilling of SiCp/AL6063

1.
School of Mechanical and Electrical Engineering, North China Institute of Aerospace Engineering, 133 Aimin East Road, Langfang, Hebei, China
2.
Department of Additive Manufacturing, Beijing Spacecrafts Manufacturing Factory, 104 Youyi road, Haidian District, Beijing, China

Academic Editor: Timon Rabczuk

Received: 25 September 2022 Revised: 06 November 2022 Accepted: 07 November 2022 Published: 25 November 2022

Thrust force and metal chips are essential focuses in SiCp/AL6063 drilling operations. Compared with conventional drilling (CD), the ultrasonic vibration-assisted drilling (UVAD) has attractive advantages: for instance, short chips, small cutting forces, etc. However, the mechanism of UVAD is still inadequate, especially in the thrust force prediction model and numerical simulation. In this study, a mathematical prediction model considering the ultrasonic vibration of the drill is established to calculate the thrust force of UVAD. A 3D finite element model (FEM) for the thrust force and chip morphology analysis is subsequently researched based on ABAQUS software. Finally, experiments of CD and UVAD of SiCp/Al6063 are performed. The results show that when the feed rate reaches 151.6 mm/min, the thrust force of UVAD decreases to 66.1 N, and width of the chip decreases to 228 um. As a result, the errors of the mathematical prediction and 3D FEM model of UVAD are about 12.1 and 17.4% for the thrust force, and the errors of the CD and UVAD of SiCp/Al6063 are 3.5 and 11.4% for the chip width, respectively. Compared with the CD, UVAD could reduce the thrust force and improve chip evacuation effectively.
- UVAD,
- mathematical prediction model,
- 3D FEM,
- chip morphology
Citation: Xu Ji, Fan Bai, Jiang Jiang, Hongge Fu, Qingjie Sun, Weiyu Zhu. Numerical simulation and experimental study for ultrasonic vibration-assisted drilling of SiCp/AL6063[J]. Mathematical Biosciences and Engineering, 2023, 20(2): 2651-2668. doi: 10.3934/mbe.2023124

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Abstract

Thrust force and metal chips are essential focuses in SiCp/AL6063 drilling operations. Compared with conventional drilling (CD), the ultrasonic vibration-assisted drilling (UVAD) has attractive advantages: for instance, short chips, small cutting forces, etc. However, the mechanism of UVAD is still inadequate, especially in the thrust force prediction model and numerical simulation. In this study, a mathematical prediction model considering the ultrasonic vibration of the drill is established to calculate the thrust force of UVAD. A 3D finite element model (FEM) for the thrust force and chip morphology analysis is subsequently researched based on ABAQUS software. Finally, experiments of CD and UVAD of SiCp/Al6063 are performed. The results show that when the feed rate reaches 151.6 mm/min, the thrust force of UVAD decreases to 66.1 N, and width of the chip decreases to 228 um. As a result, the errors of the mathematical prediction and 3D FEM model of UVAD are about 12.1 and 17.4% for the thrust force, and the errors of the CD and UVAD of SiCp/Al6063 are 3.5 and 11.4% for the chip width, respectively. Compared with the CD, UVAD could reduce the thrust force and improve chip evacuation effectively.

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