Improving hole exit quality in rotary ultrasonic machining of ceramic matrix composites using a compound step-taper drill |
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| Affiliation: | 1. State Key Laboratory of Tribology, Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China;2. Beijing Key Lab of Precision/Ultra-precision Manufacturing Equipments and Control, Beijing 100084, China;3. Division of Advanced Manufacturing, Graduate School at Shenzhen, Tsinghua University, Shenzhen 518055, China;4. Beijing Xinghang Mechanical-Electrical Equipment Co., Ltd., Beijing 100074, China;1. Key Laboratory of Advanced Ceramics and Machining Technology, Tianjin University, Ministry of Education, People''s Republic of China;2. Department of Mechanical Engineering, College of Engineering, Boston University, United States;1. State Key Laboratory of Tribology, Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China;2. Beijing Key Lab of Precision/Ultra-precision Manufacturing Equipments and Control, Beijing 100084, China;3. Division of Advanced Manufacturing, Graduate School at Shenzhen, Tsinghua University, Shenzhen 518055, China;1. Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China;2. Beijing Institute of Electronic System Engineering, Beijing 100854, China;3. Beijing Key Lab of Precision/Ultra-precision Manufacturing Equipment and Controls, Beijing 100084, China;4. Department of Industrial and Manufacturing Systems Engineering, Kansas State University, Manhattan, KS 66506, USA;1. Key Laboratory of High Efficiency and Clean Mechanical Manufacture of MOE, School of Mechanical Engineering, Shandong University, Jinan 250061, Shandong Province, PR China;2. School of Mechanical Engineering, Southeast University, Nanjing 211189, Jiangsu Province, PR China;1. Jiangsu Key Laboratory and Micro-Manufacturing Technology, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China;2. Beijing Xinghang Mechanical and Electrical Equipment Co., Ltd., Beijing 100000, China |
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| Abstract: | Mechanical-machining-induced tearing defects at hole exits restrict the application of C/SiC composites. Rotary ultrasonic machining (RUM) is suitable for hole manufacture in brittle composites, providing reduced tearing size as compared with conventional grinding. Even so, substantial tearing defects at the hole exit remain with RUM. In this study, a novel compound step-taper diamond core drill for RUM of C/SiC was developed to further improve the hole exit quality. Contrastive machining tests were conducted to evaluate the effectiveness of the new type drill. Experimental results show that the compound drill can help reduce the tearing size by 30% on average. Results of variance analysis indicate that there is little dependency of tearing size on processing variables with the compound drill, whereas the common drill shows substantial dependence. Detailed observation of the thrust force reveals that the tearing size reduction using the compound drill is due to the reprocessing effects of its taper face. In the reprocessing process of the taper face, the thrust force gradually decreases at the hole exit. Increasing the ultrasonic amplitude can help further improve the hole exit quality when using our compound drill. |
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| Keywords: | Rotary ultrasonic machining Hole exit quality Drill design Ceramics matrix composites Hole drilling C/SiC |
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