Understanding the material removal mechanism in ultrasonic vibration-assisted drilling (UVAD) is essential in maximizing its productivity in the machining of metals and various difficult-to-cut materials. Thus, this thesis investigates the mechanism through kinematics and chip formation study. The kinematic model of ultrasonic vibration-assisted drilling is first derived based on tool edge geometry and cutting parameters including spindle speed, feed per tooth, oscillation frequency and amplitude to arrive at oscillating rake angle, clearance angle and penetration angle as a function of cutting point radius. It is shown that the high penetration angle results in a wiping effect due to tool flank-work interference and leads to a machined surface with a saw-tooth profile. The machined surface profile is derived and analyzed as functions of penetration angle and tool edge geometry. The uncut chip thickness model is derived based on the machined surface profile and is shown to be characterized by a saw-tooth profile and the phase angle between two successive cuts. The ultrasonic vibration-assisted milling experiment is performed to verify the cutting point kinematics and saw-tooth profile of the machined surface. The main characteristics of the machined surface are found to agree well with the predicted results except for the saw-tooth height. The experimental saw-tooth height was shown to be smaller than the prediction due to reduced oscillation amplitude from the loading effect of the ultrasonic vibration device. Drilling experiments with and without UVAD are performed and compared under various spindle speeds and feed rates. It is found that the oscillations affect chip formation in terms of topology and morphology while also improving the chip breaking and evacuation process. The thrust force and cutting torque are found experimentally to be reduced in ultrasonic vibration-assisted drilling as the result of better chip breaking and evacuation.

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