Study on the Simulation and Experiment of Ultrasonic-assisted Vibration Drilling of Ti6Al4V

Abstract Titanium alloy is a typical difficult-to-cut material used in most industrial fields, so its machinability is characterized by low efficiency and poor quality using Conventional Drilling (CD). To address this issue in drilling workpiece of Ti6Al4V the ultrasonic vibration with high-frequency and low-amplitude is applied in the feeding direction of drill bit. Based on Johnson-cook constitutive model of workpiece material, a 3D FEM cutting simulation is conducted to analyse the variation trend of thrust force and the formation of hole burr under different processing parameters. The simulation and experimental results demonstrate that the ultrasonic vibration can convert continuous cutting into periodical intermittent cutting, which is helpful to break chip and deburr as well as enhance inner wall quality of hole significantly. Moreover, ultrasonic assisted drilling decreases the thrust force, improves the rigidity of the cutting tool in the process of drilling and facilitates removing the workpiece material. Therefore, the ultrasonic vibration can effectively promote the drilling quality of titanium alloys Ti6Al4V compared with CD.

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