Comparative study on drilling effect between conventional drilling and ultrasonic-assisted drilling of Ti-6Al-4V/Al2024-T351 laminated material

This paper investigates the performance of ultrasonic-assisted drilling (UAD) in machining of Ti-6Al-4V/Al2024-T351 laminated material by using DEFORM-3D finite element method. The effectiveness of two key parameters, frequency and spindle speed, is discussed. The purpose is to explore the effect of UAD on machining performance, to compare it with conventional drilling (CD) and to prove that the UAD technique could achieve better hole quality. To be more specific, the following aspects are taken into account: chip morphology, layer delamination, thrust force, temperature change, and effective stress. The result shows that UAD can produce fragile chips, smaller layer delamination, lower thrust force, larger maximum temperature, and lower effective stress. Both frequency and spindle speed have influence in their own way on machining process.