Vibration Drilling of Al2024-T6

Vibration drilling (VD) is a process in which longitudinal wave is used to improve drilling conditions. In this process, longitudinal wave with high frequency and low amplitude is applied on tool while engagement between tool and workpiece during machining process is connected and disconnected. In this study, a rotary VD tool was designed and fabricated for performing VD. This tool is able to apply longitudinal wave through an ultrasonic transducer and horn to a drill in a rotary mechanism. After primary tests and confidence from proper design and fabrication of this tool, the effect of longitudinal wave in VD of Al2024-T6 was studied and compared with ordinary drilling (OD). Some parameters such as the thrust force, chip, and burr were measured and compared together in both conventional and ultrasonic methods. The obtained results demonstrate a substantial reduction in thrust force with VD rather than OD.