Modeling and experimental investigation of drilling force for low-frequency axial vibration-assisted BTA deep hole drill
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ORIGINAL ARTICLE
Modeling and experimental investigation of drilling force for low-frequency axial vibration-assisted BTA deep hole drilling Xubo Li 1,2 & Jianming Zheng 1 & Yan Li 1 & Jiming Xiao 1 & Bian Guo 1,2 & Chi Liu 1 Received: 22 July 2019 / Accepted: 24 September 2020 / Published online: 16 October 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract The ability to form regular chips and evacuate them smoothly is crucial for deep hole drilling. In this work, an eccentric cam mechanism is used to apply low-frequency axial vibration at the end of the drill tube for boring and trepanning association (BTA) deep hole machining, and the instantaneous cutting thickness equation of low-frequency axial vibration assisted drilling is derived, which can actively control the length of the chip and achieve a good chip removal effect. Considering the variable geometric parameters and the scale effect of teeth cutting, a new analytical model is established to obtain the instantaneous drilling force of staggered teeth BTA deep hole drill assisted by low-frequency axial vibration. The relevant parameters in drilling force model are identified, and the distribution laws of the normal friction angle, normal shear angle, and shear stress with instantaneous cutting layer thickness and drilling radius values are achieved. The influence of the vibration drilling process parameters, including feed, speed, amplitude, and frequency ratio, on the drilling force is investigated experimentally, and the validity of the drilling force model is verified. These results show that the drilling force model is reliable, and the thrust and torque of the low-frequency axial vibration assisted drilling relative to ordinary drilling are reduced by 21.63% and 13.74%, respectively. Keywords Staggered teeth BTA drill . Deep hole drilling . Vibration drilling . Drilling force
1 Introduction Staggered teeth boring and trepanning association (BTA) deep hole drilling is often used for deep hole machining with high precision and large length-to-diameter ratio [1, 2]. Inconel690 is widely used in energy, aerospace, and petrochemical industries as a high-temperature structural material due to its excellent fatigue resistance, durability, and oxidation resistance under high-temperature conditions [3, 4]. For the limitation of the cross section area of the chip discharge channel, the fracture and discharge of chips become a key point in deep hole drilling, and chip fracture is more difficult in the
* Jianming Zheng [email protected] 1
School of Mechanical and Precision Instrument Engineering, Xi’an University of Technology, Xi’an 710048, China
2
College of Mechanical Engineering, Baoji University of Arts and Sciences, Baoji 721016, China
machining of Inconel-690 that has strong toughness and plasticity, directly affecting the deep hole machining efficiency [5–8]. The low-frequency vibration in the feed direction is applied at the end of the drill tube to assist staggered teeth BTA deep hole drilling to realize intermittent cutting t
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