Vibration drilling tool and thrust force investigation in vibratory drilling process of Al 2024-T6

Vibratory drilling (VD) process is a new modern technology where longitudinal wave with high frequency (more than 16 kHz) and low amplitude (usually between 2 up to 30 µm) is superimposed on the movement of cutting tool، resulting in connection and disconnection of cutting tool engagement with workpiece. In this study، in order to perform vibratory drilling process، two vibration tools are designed and fabricated. ANSYS software is used to accomplish modal analysis. Using this software، it is possible to design vibration tools (horn and drill) to have resonance frequency equals to transducer frequency. A rotary mechanism is designed to perform vibratory drilling on a lathe machine. This set-up is able to do vibratory drilling process while both vibration and rotation are applied to the movement of drill. This mechanism (rotary vibratory drilling) has ability to drill various workpiece with different sizes and materials. After primary tests، the effect of is able drilling is studied and compared with conventional drilling while specimen is Al2024-T6. Thrust force and chip morphology are two studied parameters in this paper. The obtained results showed a notable reduction of thrust force in vibratory drilling process over the conventional one.