Modeling and experimental analysis of ultrasonic vibration drilling force prediction model for tiny small holes in high body fraction aluminum-based silicon carbide composites

The high-volume SiCp/Al (65%) composite material possesses excellent properties of both aluminum alloy and SiC. Its drilling process is widely utilized in various fields such as the national defense industry, electronic communication, aerospace, etc. Drilling with ultrasonic vibrations has shown promising results when used for high-volume drilling in SiCp/Al. Because of the strong correlation between drilling force and hole quality, it is very important to predict the drilling force to optimize the drilling parameters to improve the processing quality and efficiency. However, the prediction of drilling force for high volume fraction SiCp/Al in UVAD is still a problem. This study establishes a theoretical mechanical model that considers ultrasonic vibration and undeformed cutting thickness. Especially, the main cutting edge and the transverse edge of the drill bit are divided into several small units. The cutting force and torque of each unit are solved using oblique cutting theory and orthogonal theory, and the axial force and torque of the drill bit as a whole are calculated using the integration method. This model not only considers the influence of ultrasonic vibration on drilling force but also introduces a new reference, undeformed cutting thickness. In addition, a three-dimensional simulation model was established. Finally, the effectiveness of the theoretical drilling force model and simulation model in predicting axial force and torque during the drilling process of SiCp/Al composite materials was verified through experiments. The average error of the three-dimensional model in predicting axial force was 7.11%, and the average error of torque was 7.19%. The average error of the mechanical model in predicting axial force was 10.49%, and the average error of torque was 13.05%.