Introducing transversal vibration in twist drilling: Material removal mechanisms and surface integrity

In twist drilling, severe extrusion is unavoidable at the chisel edge zone and results in high thrust force and poor surface integrity. Traditional axial vibration-assisted twist drilling only modifies the material removed from the continuous extrusion to the interrupted extrusion for the chisel edge centre, and must satisfy the chip-breaking conditions to ensure that the cutting edge is periodically separated from the workpiece. Hence, transversal vibration, has been introduced in twist drilling to overcome the severe extrusion behaviour of the chisel edges of the twist drills, referred to as ultrasonic transversal vibration-assisted drilling (UTVD). Theoretical models revealed that the material removal behaviour of the chisel edge centre changed from extrusion in CD to cutting in UTVD. Experiments were performed on UTVD of Ti-6Al-4V to confirm the feasibility with this novel method. The results indicated that transverse vibration significantly affected the thrust force and torque, and the maximum decline was 29.4% and 31.5%, respectively, compared with CD. Generated chips verified the material removal behaviour of the chisel edge centre zone changed from extrusion in CD to cutting in UTVD. Therefore, the hole quality and surface integrity were improved significantly by UTVD. Deeper plastic deformation (similar to 2.5 times), higher surface microhardness and compressive residual stress were realised using UTVD. This study enhanced the understanding of material removal and formation mechanisms of the surface and subsurface in UTVD, thereby providing a novel method and theoretical basis for the high-performance twist drilling of difficult-to-cut alloys.