Minimization of the hole overcut and cylindricity errors during rotary ultrasonic drilling of Ti-6Al-4V

Titanium and its alloys e.g. Ti6Al4V have widespread applications in aerospace, automotive and medical industry. At the same time titanium and its alloys are regarded as difficult to machine materials due to their high strength and low thermal conductivity. Significant efforts have been dispensed to improve the accuracy of the machining processes for Ti6Al4V. The current study present the use of the rotary ultrasonic drilling (RUD) process for machining high quality holes in Ti6Al4V. The study takes into account the effects of the main RUD input parameters including spindle speed, ultrasonic power, feed rate and tool diameter on the key output responses related to the accuracy of the drilled holes including cylindricity and overcut errors. Analysis of variance (ANOVA) was employed to study the influence of the input parameters on cylindricity and overcut error. Later, regression models were developed to find the optimal set of input parameters to minimize the cylindricity and overcut errors.