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<p>GH4169 is a nickel-based superalloy renowned for its excellent resistance to high temperatures, corrosion, and fatigue. Due to these properties, it is widely used in the aerospace industry for manufacturing hot-section components, particularly turbine blades in aero-engines. Air film holes are critical structural features in turbine blades, but burr formation commonly occurs during the drilling process. This study investigates the mechanism of burr formation in conventional drilling (CD) and ultrasonic vibration-assisted drilling (UAD). An analytical model is developed to predict the evolution of burr height in UAD based on the principle of energy conservation. The proposed framework combines dynamic cutting mechanics with plastic deformation energy dissipation, establishing quantitative correlations between machining parameters and burr height. Experimental results show that, at a spindle speed of 9000&#xa0;rpm and a feed rate of 5&#xa0;mm/min, UAD with a vibration amplitude of 6&#xa0;μm reduces the axial force from 13.29 N (in CD) to 7.34 N, corresponding to a 44.75% decrease. Moreover, the burr height decreases from 36.13 to 28&#xa0;μm, representing a 22.5% reduction. The burr morphology also changes, forming a ring of thin, curved burrs at the hole exit. To quantify the influence of machining parameters on burr dimensions, multivariate regression analysis (MRA) was employed, and the material removal rate (MRR) was also calculated. Through parameter optimization, an optimal set of ultrasonic micro-drilling conditions was determined: ultrasonic amplitude of 6&#xa0;μm, feed rate of 6.3&#xa0;mm/min, and spindle speed of 9000&#xa0;rpm. This configuration effectively suppresses burr formation while maintaining a high material removal rate.</p>

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Prediction and suppression of exit burr height in ultrasonic vibration-assisted micro-drilling of GH4169 superalloy

  • 期刊论文

  • 发表日期：

    2025年8月19日

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  • Dingyi Tao,
  • Zhen Yin,
  • Qinglong An,
  • Mengqiu Yu,
  • Zixin Yu,
  • Qing Miao,
  • Chenwei Dai,
  • Ming Zhang,
  • Hua Li

摘要

GH4169 is a nickel-based superalloy renowned for its excellent resistance to high temperatures, corrosion, and fatigue. Due to these properties, it is widely used in the aerospace industry for manufacturing hot-section components, particularly turbine blades in aero-engines. Air film holes are critical structural features in turbine blades, but burr formation commonly occurs during the drilling process. This study investigates the mechanism of burr formation in conventional drilling (CD) and ultrasonic vibration-assisted drilling (UAD). An analytical model is developed to predict the evolution of burr height in UAD based on the principle of energy conservation. The proposed framework combines dynamic cutting mechanics with plastic deformation energy dissipation, establishing quantitative correlations between machining parameters and burr height. Experimental results show that, at a spindle speed of 9000 rpm and a feed rate of 5 mm/min, UAD with a vibration amplitude of 6 μm reduces the axial force from 13.29 N (in CD) to 7.34 N, corresponding to a 44.75% decrease. Moreover, the burr height decreases from 36.13 to 28 μm, representing a 22.5% reduction. The burr morphology also changes, forming a ring of thin, curved burrs at the hole exit. To quantify the influence of machining parameters on burr dimensions, multivariate regression analysis (MRA) was employed, and the material removal rate (MRR) was also calculated. Through parameter optimization, an optimal set of ultrasonic micro-drilling conditions was determined: ultrasonic amplitude of 6 μm, feed rate of 6.3 mm/min, and spindle speed of 9000 rpm. This configuration effectively suppresses burr formation while maintaining a high material removal rate.