Analysis of burr height in ultrasonic-assisted drilling of Ti-6Al-4V alloy

In this study, the robust design of ultrasonic-assisted drilling (UAD) parameters for twist drills deals with the burr height in drilling Ti-6A1-4V alloy. The optimum combinations between the various drilling factors can be identified using Taguchi methods and orthogonal array. Experimental results show the optimum conditions were the frequency tracing of ON, operating voltage of 400V, drill diameter of 2.5 mm, feed rate of 20 mm/min and spindle speed of 700 rpm. The drill diameter, feed rate and frequency tracing are the most significant factors among the five controllable factors affecting the burr height in UAD of Ti-6A1-4V alloy. The frequency tracing provides the possibility of self-tuning the drilling system to keep the resonant mode of oscillations under variable conditions. The LabVIEW software provides features for control and monitoring of the frequency tracing operation, which cover the essential needs of research and application. This feature is vital for obtaining consistent results during UAD.