Effect of longitudinally intermittent movement of cutting tool in drilling of AISI 1045 steel: A three-dimensional numerical simulation

Abstract

Applying ultrasonic vibrations in machining process is an effective method to improve desired machinability factors. In this study, a three-dimensional finite element model is developed to evaluate effect of added vibratory movement of cutting tool on output parameters in conventional drilling of AISI 1045 steel. Heat generation on drill faces, strain, and damage of deformed chip in addition to thrust force are taken into account to be analyzed. Besides, a dynamometer and a vision measuring microscope are used to investigate generated thrust force and built-up edge during conventional and ultrasonic-assisted drilling. As a result, it is shown that vibratory movement of drill bit results in lower temperature to be generated on tool faces resulting in almost elimination of built-up edge. Moreover, higher damage value resulted by additional chip bending is observed when ultrasonic vibration is added to the operation.