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<p>As a typical difficult-to-machine material, titanium alloys have important application value in the aerospace field. However, in conventional deep-hole drilling processes, their low thermal conductivity combined with high chemical activity results in chip evacuation difficulties, poor hole exit quality, and reduced tool life, which seriously affect machining efficiency and product quality. To address these challenges, an ultrasonic vibration-assisted drilling (UVAD) process was used in drilling a deep hole in titanium alloy. Firstly, the device was designed based on Newtonian dynamics and validated through finite element modal and harmonic response analyses, ensuring coordinated displacements of the horn, drill bit, and supporting flange under resonance. Drilling experiments were then conducted, where exit burr morphology was quantitatively evaluated via image threshold segmentation to analyze the effects of spindle speed, ultrasonic amplitude, and feed rate. Tool wear was assessed through flank wear measurement, and acceleration signal analysis was used to further verify the potential of ultrasonic vibration in extending tool life. Results show that, compared with conventional drilling (CD), ultrasonic vibration-assisted drilling (UVAD) reduced exit burr area by 72.5% on average, and decreased VB values by 72.3–72.7% at spindle speeds of 4000–5000&#xa0;rpm. Acceleration analysis further revealed reduced vibration fluctuations, confirming improved process stability and tool life potential. Overall, UVAD significantly enhances the tool–workpiece interaction mechanism in titanium alloy deep-hole drilling, offering an effective approach to improve efficiency, stability, and hole quality.</p>

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Design of ultrasonic vibration device and its experimental study on micro-deep-hole drilling

  • 期刊论文

  • 发表日期：

    2025年10月15日

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  • Xinli Liu,
  • Chen Zhang,
  • Rubo Wu,
  • Yiqing Shi

摘要

As a typical difficult-to-machine material, titanium alloys have important application value in the aerospace field. However, in conventional deep-hole drilling processes, their low thermal conductivity combined with high chemical activity results in chip evacuation difficulties, poor hole exit quality, and reduced tool life, which seriously affect machining efficiency and product quality. To address these challenges, an ultrasonic vibration-assisted drilling (UVAD) process was used in drilling a deep hole in titanium alloy. Firstly, the device was designed based on Newtonian dynamics and validated through finite element modal and harmonic response analyses, ensuring coordinated displacements of the horn, drill bit, and supporting flange under resonance. Drilling experiments were then conducted, where exit burr morphology was quantitatively evaluated via image threshold segmentation to analyze the effects of spindle speed, ultrasonic amplitude, and feed rate. Tool wear was assessed through flank wear measurement, and acceleration signal analysis was used to further verify the potential of ultrasonic vibration in extending tool life. Results show that, compared with conventional drilling (CD), ultrasonic vibration-assisted drilling (UVAD) reduced exit burr area by 72.5% on average, and decreased VB values by 72.3–72.7% at spindle speeds of 4000–5000 rpm. Acceleration analysis further revealed reduced vibration fluctuations, confirming improved process stability and tool life potential. Overall, UVAD significantly enhances the tool–workpiece interaction mechanism in titanium alloy deep-hole drilling, offering an effective approach to improve efficiency, stability, and hole quality.