Figure 1.
Schematic diagram of EDM piercing.
Figure 1.
Schematic diagram of EDM piercing.
Figure 2.
Schematic diagram of ultrasonic milling principle.
Figure 2.
Schematic diagram of ultrasonic milling principle.
Figure 3.
Schematic diagram of ultrasonic machining system.
Figure 3.
Schematic diagram of ultrasonic machining system.
Figure 5.
Ultrasonic milling system. (a) Ultrasonic shank and wireless energy transferring; (b) Ultrasonic generator; (c) Milling system.
Figure 5.
Ultrasonic milling system. (a) Ultrasonic shank and wireless energy transferring; (b) Ultrasonic generator; (c) Milling system.
Figure 6.
Test drill diagram.
Figure 6.
Test drill diagram.
Figure 7.
Ultrasonic micro-hole machining of GH4169 plate.
Figure 7.
Ultrasonic micro-hole machining of GH4169 plate.
Figure 8.
0.5 mm micro-hole machining results on GH4169 plate under ultrasonic vibration.
Figure 8.
0.5 mm micro-hole machining results on GH4169 plate under ultrasonic vibration.
Figure 9.
Dimensions and roundness analysis of 0.5 mm micro-hole machining results on GH4169 plate.
Figure 9.
Dimensions and roundness analysis of 0.5 mm micro-hole machining results on GH4169 plate.
Figure 10.
GH4169 plate ultrasonic 0.4 micro-hole machining results.
Figure 10.
GH4169 plate ultrasonic 0.4 micro-hole machining results.
Figure 11.
Dimensional and roundness analysis of ultrasonic 0.4 micro-hole machining of GH4169 plate.
Figure 11.
Dimensional and roundness analysis of ultrasonic 0.4 micro-hole machining of GH4169 plate.
Figure 12.
Results of ultrasonic 0.3 micro-hole machining of GH4169 plates.
Figure 12.
Results of ultrasonic 0.3 micro-hole machining of GH4169 plates.
Figure 13.
Analysis of size and roundness of ultrasonic 0.3 micro-hole machining of GH4169 sheet.
Figure 13.
Analysis of size and roundness of ultrasonic 0.3 micro-hole machining of GH4169 sheet.
Figure 14.
Results of ultrasonic 0.2 mm micro-hole machining of GH4169 plates.
Figure 14.
Results of ultrasonic 0.2 mm micro-hole machining of GH4169 plates.
Figure 15.
Dimensional and roundness analysis of ultrasonic 0.2 mm micro-hole machining of GH4169 plate.
Figure 15.
Dimensional and roundness analysis of ultrasonic 0.2 mm micro-hole machining of GH4169 plate.
Figure 16.
Effect of machining parameters on hole taper: (a) Effect of rotational speed on hole taper; (b) Effect of feed rate on hole taper.
Figure 16.
Effect of machining parameters on hole taper: (a) Effect of rotational speed on hole taper; (b) Effect of feed rate on hole taper.
Figure 17.
Effect of machining parameters on average axial force: (a) Effect of rotational speed on axial force; (b) Effect of feed rate on axial force.
Figure 17.
Effect of machining parameters on average axial force: (a) Effect of rotational speed on axial force; (b) Effect of feed rate on axial force.
Figure 18.
Effect of machining parameters on average axial force: (a) Effect of speed on average burr height; (b) Effect of feed rate on average burr height.
Figure 18.
Effect of machining parameters on average axial force: (a) Effect of speed on average burr height; (b) Effect of feed rate on average burr height.
Figure 19.
Effect of machining parameters on surface roughness: (a) Effect of rotational speed on surface roughness; (b) Effect of feed rate on surface roughness.
Figure 19.
Effect of machining parameters on surface roughness: (a) Effect of rotational speed on surface roughness; (b) Effect of feed rate on surface roughness.
Figure 20.
Hole wall shape of traditional drilling and UAD: (a) Hole wall shape in traditional drilling; (b) Hole wall shape in UAD.
Figure 20.
Hole wall shape of traditional drilling and UAD: (a) Hole wall shape in traditional drilling; (b) Hole wall shape in UAD.
Figure 21.
Comparison between conventional drilling and UAD bit wear: (a) Wear of conventional drilling bits; (b) Ultrasonic vibration assisted drilling bit wear.
Figure 21.
Comparison between conventional drilling and UAD bit wear: (a) Wear of conventional drilling bits; (b) Ultrasonic vibration assisted drilling bit wear.
Figure 22.
EDM results: (a) 0.1 micro-hole optical solid image; (b) 0.1 micro-hole optical swept surface imaging.
Figure 22.
EDM results: (a) 0.1 micro-hole optical solid image; (b) 0.1 micro-hole optical swept surface imaging.
Figure 23.
UAD machining results: (a) 0.1 micro-hole optical solid image; (b) 0.1 micro-hole optical swept surface image.
Figure 23.
UAD machining results: (a) 0.1 micro-hole optical solid image; (b) 0.1 micro-hole optical swept surface image.
Table 1.
Common small hole machining methods.
Table 1.
Common small hole machining methods.
Traditional Method | Non-Traditional Methods |
---|
Drilling, reaming, water jet machining, abrasive jet machining, punching, boring, end milling, honing, milling inner cavity, grinding, hinge | EDM perforation, electrolytic machining, chemical machining, electropolishing machining laser machining, photochemical machining, ion beam machining, ultrasonic machining |
Table 2.
Cutting parameters of tools and machine tools.
Table 2.
Cutting parameters of tools and machine tools.
Drill Diameter | Spindle Speed | Feed Speed |
---|
Φ0.2 mm, Φ0.3 mm, Φ0.4 mm, Φ0.5 mm | 10,000 rpm | 15–30 mm/min |
Table 3.
GH4169 plate ultrasonic 0.5 micro-hole machining measured values.
Table 3.
GH4169 plate ultrasonic 0.5 micro-hole machining measured values.
Hole Serial Number | 1# | 2# | 3# | 4# | 5# | 6# | 7# | 8# | 9# |
---|
Diameter (mm) | 0.5027 | 0.5023 | 0.5025 | 0.5075 | 0.5032 | 0.5014 | 0.5043 | 0.5033 | 0.5038 |
Roundness | 0.0068 | 0.0057 | 0.0056 | 0.0055 | 0.0081 | 0.0025 | 0.0056 | 0.0050 | 0.0063 |
Table 4.
GH4169 plate ultrasonic 0.4 micro-hole machining measured values.
Table 4.
GH4169 plate ultrasonic 0.4 micro-hole machining measured values.
Hole Serial Number | 1# | 2# | 3# | 4# | 5# | 6# | 7# | 8# | 9# |
---|
Diameter (mm) | 0.4000 | 0.4044 | 0.4041 | 0.4037 | 0.4025 | 0.4001 | 0.4038 | 0.4046 | 0.4061 |
Roundness | 0.0040 | 0.0068 | 0.0058 | 0.0058 | 0.0044 | 0.0027 | 0.0061 | 0.0051 | 0.0042 |
Table 5.
GH4169 plate ultrasonic 0.3 micro-hole machining actual measured values.
Table 5.
GH4169 plate ultrasonic 0.3 micro-hole machining actual measured values.
Hole Serial Number | 1# | 2# | 3# | 4# | 5# | 6# | 7# | 8# | 9# |
---|
Diameter (mm) | 0.3043 | 0.3071 | 0.3055 | 0.3040 | 0.3073 | 0.3064 | 0.3059 | 0.3083 | 0.3055 |
Roundness | 0.0038 | 0.0047 | 0.0050 | 0.0068 | 0.0045 | 0.0045 | 0.0056 | 0.0043 | 0.0041 |
Table 6.
GH4169 plate ultrasonic 0.2 micro-hole machining actual measured values.
Table 6.
GH4169 plate ultrasonic 0.2 micro-hole machining actual measured values.
Hole Serial Number | 1# | 2# | 3# | 4# | 5# | 6# | 7# | 8# | 9# |
---|
Diameter (mm) | 0.2066 | 0.2027 | 0.2004 | 0.2074 | 0.2021 | 0.2028 | 0.2082 | 0.2075 | 0.2064 |
Roundness | 0.0067 | 0.0082 | 0.0088 | 0.0058 | 0.0085 | 0.0086 | 0.0062 | 0.0041 | 0.0045 |
Table 7.
Cutting parameters of tool and machine.
Table 7.
Cutting parameters of tool and machine.
Ultrasonic Toolholder System | Ultrasound Frequency | Drill Diameter | Spindle Speed | Feeding Speed |
---|
CKN-XH | 30 ± 1 kHZ | Φ0.1 | 10,000 rpm | 15–30 mm/min |
Table 8.
Test results of two machining methods.
Table 8.
Test results of two machining methods.
Category | UAD | Drill Diameter |
---|
Diameter (mm) | 1.006 | 1.012 |
Roundness (mm) | 0.006 | 0.014 |
Burr height (mm) | 0.035 | 0.011 |