Vibration excitation and energy transfer during ultrasonically assisted drilling

Successful application of ultrasonically assisted drilling needs dynamic matching of the transducer with the drill bit considered as a continuous system loaded by the nonlinear processing load. When using standard tools this leads to the compatible choice of the transducer and accurate matching of the transducer and tool. The principal dynamical features of this matching are considered. Optimal position of excitation cross section of the drill bit, which depends on the relationship between elasto-dissipative characteristics of the transducer, the drill bit and the work load, is found in general analytical form. The optimal matching preserves the resonant tuning of the transducer and compensates the additional energy losses in the drill bit and processing. This produces also an amplification of vibration amplitude. The effect is achieved through the generation and maintenance of a nonlinear resonant mode of vibration and by active matching of the oscillating system with the dynamic loads imposed by the cutting process with the help of the intelligent electronic feedback circuitry. A prototype of an ultrasonic drilling system has been designed, manufactured. and tested. Improvements of machining characteristics due to superposition of ultrasonic vibration are demonstrated. Substantial improvements in the cutting performance of drill bits lead to benefits in drilling performance, which include faster penetration rates, reduction of tool wear, improvements in the surface finish, roundness and straightness of holes and, in ductile materials, the reduction or even complete elimination of burrs on both the entrance and exit faces of plates. The reduction in the reactive force experienced also causes greatly reduced deformation when drilling through thin, flexible plates and helps to alleviate delamination hazard.