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Design of a Retrofittable Spindle Attachment for High Frequency Vibration-Assisted Drilling

[+] Author Affiliations
J. Panju

McGill University, Montreal, QC, Canada

M. Meshreki, M. H. Attia

National Research Council Canada, Montreal, QC, Canada

Paper No. IMECE2014-39307, pp. V02AT02A034; 8 pages
doi:10.1115/IMECE2014-39307
From:
  • ASME 2014 International Mechanical Engineering Congress and Exposition
  • Volume 2A: Advanced Manufacturing
  • Montreal, Quebec, Canada, November 14–20, 2014
  • Conference Sponsors: ASME
  • ISBN: 978-0-7918-4643-8
  • Copyright © 2014 by ASME and Her Majesty the Queen in Right of Canada

abstract

Conventional drilling of modern super alloys and composite material induces high stresses in the vicinity of drilled holes along with high thrust forces which lead to problems in terms of hole quality and accuracy as well as increased tool wear. A recent and promising technique to overcome these challenges is to introduce vibration assistance in the cutting zone by superimposing oscillating vibration in the feed direction of the tool. Two regimes of vibration excitation could be applied for this purpose: low frequency (<500 Hz) high amplitude (>100 μm) and high frequency (>500 Hz) low amplitude (<20 μm). Motivated by the advantages of the HF-VAD and the limited work available in the literature for this regime, a new system is developed by the authors where the rotating tool is excited to high frequency and low amplitude. The new design is based on the use of piezoelectric actuators to generate the motion and a high speed slip ring to ensure the transfer of sufficient power to the actuator. A novel concept was implemented by de-coupling the rotary motion of the spindle from the vibrational motion of the actuator to ensure a higher efficiency of power transmission without damaging either the actuator or the spindle. With this design, a retrofittable HSK 100A toolholder with high frequency excitation spindle attachment was manufactured to incorporate drill sizes up to 1/4 inches. Commissioning tests were performed under no load and spring loaded conditions and it was found that the system has a capability to excite the tool up to 100 μm at 900 Hz (resonance frequency) and up to 5 μm between 500–800 Hz and 1100–2500 Hz. HF-VAD tests were conducted using this new attachment on Aluminum 6061 and it was found that the system was able to successfully obtain the prescribed frequency and amplitude. Up to 50% reduction in thrust forces was obtained in HF-VAD in comparison to conventional drilling under same cutting parameters; this is associated with finer chips with break off serrations.

Copyright © 2014 by ASME and Her Majesty the Queen in Right of Canada
Topics: Drilling , Design , Vibration

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