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        Chip Control Analysis in Low-Frequency Vibration-Assisted Drilling of Ti–6Al–4V Titanium Alloys

        Haojun Yang,Yan Chen,Jiuhua Xu,Mathieu Ladonne,Julian Lonfier,Wenfeng Ding 한국정밀공학회 2020 International Journal of Precision Engineering and Vol.21 No.4

        In this study, control research of chip morphology and removal is conducted theoretically and experimentally on the basis ofthe low-frequency vibration-assisted drilling process of titanium alloy. The chip morphology prediction model is establishedon the basis of the modifi ed kinematic model, in which the shear angle variation, critical cutting thickness, and stiff ness ofa vibration generator system are considered. In terms of chip removal monitoring, a new monitoring method based on highspeed camera is proposed in this paper. And the reliability of the new method is verifi ed by comparing the signals obtainedby the power sensor and the force sensor. An empirical prediction model for chip removal is also established on the basis ofthe modifi ed kinematical model, the chip morphology prediction model, and the force balance analysis of fragmental chips. Validation experiments show that the mean error of chip radian, which can refl ect the diff erence between the predicted chipmorphology and the experimental one, is 6%. The mean error of the predicted chip removal index compared with the experimentalone is 10.4%. The results obtained show that chip removal can be controlled eff ectively by low rotation speed, smallchip radian, light chip weight, high minimum quantity lubrication cooling pressure, and high oscillation frequency. On thebasis of the prediction model of chip removal, the eff ects of drilling parameters on chip removal behavior are analyzed, andthe optimal drilling parameter combination with highest processing effi ciency is given.

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