Experimental Research of High-Quality Drilling Based on Ultrasonic Vibration-Assisted Machining

Micro-hole is widely used in various fields, and common machining methods of micro-hole in factories are drilling and electrical discharge machining (EDM), but because of low machining efficiency, these methods cannot meet requirements. Therefore, it is urgent to investigate a high efficient micro-hole machining technology to meet the demands of micro-hole machining in factory. Over past few decades, ultrasonic machining technology has developed rapidly and achieved good results in solving many critical machining problems in field of difficult-to-cut materials. Therefore, this paper builds an ultrasonic vibration-assisted drilling (UAD) experiments platform to combine micro-fine small hole drilling with ultrasonic machining technology for micro-hole multi-factor experimental research. Results show that UAD machining of micro-hole below diameter 0.5 mm is comparable to conventional drilling machining because of its high-frequency pulse intermittent cutting process, stable change in machining diameter, good stability of parameters such as shape tolerance roundness and cylindricity, small cutting force during cutting, small tool wear, and small surface roughness of inner wall of micro-hole. Compared with EDM, UAD has high efficiency and good stability of parameters such as diameter and roundness of shape tolerance. Comprehensive analysis of UAD can be used as an alternative technology solution for machining small holes in non-special requirements of metal materials in factory and has technical feasibility of stable batch production.

Automated summary

Micro-hole is widely used in various fields, and the common machining methods in factories, which are drilling and electrical discharge machining (EDM), cannot meet the requirements due to their low efficiency. Therefore, this paper investigates an efficient micro-hole machining technology by combining ultrasonic machining with micro-fine small hole drilling. The results show that ultrasonic vibration-assisted drilling (UAD) has comparable performance to conventional drilling in machining micro-holes below 0.5 mm, with stable machining diameter, good shape tolerance, small cutting force, tool wear, and surface roughness of inner wall. Compared to EDM, UAD has higher efficiency and better stability in terms of diameter and shape tolerance. It is concluded that UAD can be used as an alternative technology for machining small holes in non-special requirements of metal materials in factories with technical feasibility for stable batch production.