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<p>Zr-based bulk metallic glasses (BMGs) have demonstrated promising application potential in aerospace, microelectronics, and biomedical fields owing to their superior strength, high hardness, and excellent corrosion resistance. However, their poor thermal conductivity and extreme hardness often lead to low machining efficiency and inferior surface quality during drilling processes. This study systematically investigates the drilling characteristics of Zr-based BMGs using an integrated experimental and numerical approach. A finite element model incorporating the Drucker-Prager constitutive model was developed to predict thrust forces, the chip morphology simulation of drilling zirconium-based amorphous alloys was carried out using twist drills, and the simulation results were compared with the experimental results, with experimental validation showing excellent consistency (maximum error &lt; 5%) and consistent short helical chips, band-shaped chips and long helical chips. The effects of cutting parameters on axial force, tool wear patterns, hole wall surface roughness, and burr formation mechanisms were comprehensively analyzed. The height distribution of burrs at the entrance is −4 to 6&#xa0;μm, and that at the exit is −6 to 8&#xa0;μm. Response surface methodology (RSM) was employed to quantify parameter interactions and optimize drilling performance. The results demonstrate that under dry cutting conditions, the optimal parameter combination (spindle speed: 4117 r/min, feed speed: 3&#xa0;mm/min) achieves a significant reduction in axial force, extends tool service life remarkably, and substantially improves hole quality.</p>

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Simulation and experimental study on drilling of Zr-based BMG

  • 期刊论文

  • 发表日期：

    2026年3月30日

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  • Haoqiang Zhang,
  • Dongqi Sun,
  • Lina Wang,
  • Kaiyong Yi,
  • Yuhao Wang

摘要

Zr-based bulk metallic glasses (BMGs) have demonstrated promising application potential in aerospace, microelectronics, and biomedical fields owing to their superior strength, high hardness, and excellent corrosion resistance. However, their poor thermal conductivity and extreme hardness often lead to low machining efficiency and inferior surface quality during drilling processes. This study systematically investigates the drilling characteristics of Zr-based BMGs using an integrated experimental and numerical approach. A finite element model incorporating the Drucker-Prager constitutive model was developed to predict thrust forces, the chip morphology simulation of drilling zirconium-based amorphous alloys was carried out using twist drills, and the simulation results were compared with the experimental results, with experimental validation showing excellent consistency (maximum error < 5%) and consistent short helical chips, band-shaped chips and long helical chips. The effects of cutting parameters on axial force, tool wear patterns, hole wall surface roughness, and burr formation mechanisms were comprehensively analyzed. The height distribution of burrs at the entrance is −4 to 6 μm, and that at the exit is −6 to 8 μm. Response surface methodology (RSM) was employed to quantify parameter interactions and optimize drilling performance. The results demonstrate that under dry cutting conditions, the optimal parameter combination (spindle speed: 4117 r/min, feed speed: 3 mm/min) achieves a significant reduction in axial force, extends tool service life remarkably, and substantially improves hole quality.