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<p>This study investigates the dimensional accuracy and surface integrity problems encountered during the drilling of Al 7075 and Ti-6Al-4&#xa0;V alloys, which are widely used in the aerospace industry, and presents a systematic evaluation of ultrasonic-assisted drilling (UAD) under different amplitude levels (60%, 80%, and 100%) at constant frequency conditions. The experiments were conducted to compare conventional drilling and UAD in terms of hole diameter deviation, circularity, cylindricity, surface roughness, and burr formation. The results showed that UAD significantly improved hole quality for both materials. Hole diameter deviation decreased by 69% for Al 7075 and 59% for Ti-6Al-4&#xa0;V compared with conventional drilling. Circularity deviation was reduced by 40% for Al 7075, while cylindricity error decreased by 34% for Al 7075 and up to 54% for Ti-6Al-4&#xa0;V. Surface roughness values were improved to 0.957&#xa0;μm for Al 7075 and 0.573&#xa0;μm for Ti-6Al-4&#xa0;V. In addition, burr formation at the hole exit was substantially suppressed; the maximum burr height in Al 7075 decreased from 1479&#xa0;to 160&#xa0;μm at 100% amplitude, whereas the minimum maximum burr height obtained for Ti-6Al-4&#xa0;V under UAD conditions was 263&#xa0;μm. Multi-response optimization using the sequential least squares programming (SLSQP) algorithm identified the parameter combinations providing the best overall performance. The optimal condition for Ti-6Al-4&#xa0;V was determined as 15&#xa0;m/min cutting speed, 0.06&#xa0;mm/rev feed rate, and 100% amplitude, corresponding to the highest desirability value of 0.626. The results demonstrate that UAD effectively suppresses dimensional and geometric error mechanisms in difficult-to-machine aerospace alloys and provides a statistically supported optimization framework for precision drilling operations. The proposed approach offers a reliable basis for industrial process planning and future data-driven predictive modeling studies.</p>

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Multi-response optimization of ultrasonic-assisted drilling for ımproving hole quality in Al 7075 and Ti6Al4V alloys

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年7月13日

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  • Abdurrahman Çetin,
  • Sinan Serdar Özkan,
  • Caner Erden,
  • Furkan Korkmaz,
  • Ahmet Kolip

摘要

This study investigates the dimensional accuracy and surface integrity problems encountered during the drilling of Al 7075 and Ti-6Al-4 V alloys, which are widely used in the aerospace industry, and presents a systematic evaluation of ultrasonic-assisted drilling (UAD) under different amplitude levels (60%, 80%, and 100%) at constant frequency conditions. The experiments were conducted to compare conventional drilling and UAD in terms of hole diameter deviation, circularity, cylindricity, surface roughness, and burr formation. The results showed that UAD significantly improved hole quality for both materials. Hole diameter deviation decreased by 69% for Al 7075 and 59% for Ti-6Al-4 V compared with conventional drilling. Circularity deviation was reduced by 40% for Al 7075, while cylindricity error decreased by 34% for Al 7075 and up to 54% for Ti-6Al-4 V. Surface roughness values were improved to 0.957 μm for Al 7075 and 0.573 μm for Ti-6Al-4 V. In addition, burr formation at the hole exit was substantially suppressed; the maximum burr height in Al 7075 decreased from 1479 to 160 μm at 100% amplitude, whereas the minimum maximum burr height obtained for Ti-6Al-4 V under UAD conditions was 263 μm. Multi-response optimization using the sequential least squares programming (SLSQP) algorithm identified the parameter combinations providing the best overall performance. The optimal condition for Ti-6Al-4 V was determined as 15 m/min cutting speed, 0.06 mm/rev feed rate, and 100% amplitude, corresponding to the highest desirability value of 0.626. The results demonstrate that UAD effectively suppresses dimensional and geometric error mechanisms in difficult-to-machine aerospace alloys and provides a statistically supported optimization framework for precision drilling operations. The proposed approach offers a reliable basis for industrial process planning and future data-driven predictive modeling studies.