Variation characteristic of drilling force and influence of cutting parameter of SiCp/Al composite thin-walled workpiece

In this paper,the variation characteristic of the drilling force,and the influences of cutting speed,feed rate,and workpiece thickness on the drilling force,were eval・uated when drilling a silicon carbide particle reinforced aluminum matrix(SiCp/Al)composite thin-walled workpiece with a high volume fraction.Under the condition that the workpiece thickness was less than the drill tip height,three characteristic stages of drilling force variation were proposed.The results indicate that there is a sign币cant difference between the variations in the drilling force when drilling a thin-walled workpiece compared to thick-walled workpiece.When the chisel edge drills out the lower surface of the workpiece,there is an abrupt decrease in the thrust forces of the thin-walled and thick-walled workpieces.In addition,there is an abrupt decrease in the torque of the thick-walled workpiece,whereas that of the thinwalled workpiece increases.According to the thickness of the thin-walled workpiece,the instant of the abrupt decrease in the thrust force may lead or lag behind the theoretical instant at which the chisel edge reaches the lower surface of the workpiece without deformation.When drilling a thin-walled hole,the cutting speed has a slight influence on the thrust force,and there is a slight increase in the torque in accordance with an increase in the cutting speed.The thrust force and torque increase in accordance with an increase in the feed rate.When drilling a thinwalled workpiece with a thickness of 1 mm,the critical thickness of workpiece cracking decreases in accordance with an increase in the cutting speed,and increases in accordance with an increase in the feed rate.When drilling a thin-walled workpiece with a thickness of 0.5 mm,the concave deformation of the workpiece and the critical thickness of the workpiece cracking increase in accordance with an increase in the feed rate.However,the increment in the critical thickness of the workpiece cracking is less than that in the concave deformation of the workpiece.

Cutting force and specific energy for rotary ultrasonic drilling based on kinematics analysis of vibration effectiveness

Rotary ultrasonic drilling(RUD)has become an effective approach for machining advanced composites which are widely using in the field of aeronautics.The cutting kinematics and the corresponding material removal mechanisms are distinct in different drilling areas during RUD.However,these fundamentals have not been fully considered in the existing studies.In this research,two distinct forms of interaction induced by ultrasonic vibration were considered as impact-separation and vibratory lapping between the abrasives and workpiece.And the conditions to guarantee the effectiveness of these interactions were obtained to eliminate diminishing effects of ultrasonic vibration.Based on indentation fracture theory,the penetration depth of abrasives and the axial drilling force model was derived for RUD.The verification tests of C/SiC composites resulted in a prediction error within 15%.Due to the minimal volume of material removed during each vibration cycle,the drilling force was more stable in vibration assisted mode.The specific drilling energy of RUD was firstly calculated based on the measured drilling load.It was found the drilling parameters should be matched with vibration frequency and amplitude to make better usage of the advantages of ultrasonic vibration,which is critical in the vibration assisted processing of advanced materials.