Comprehensive analysis and modeling of ploughing effect in low-frequency vibration-assisted drilling

Low-frequency vibration-assisted drilling (LFVAD), as an advanced drilling process, has shown excellent engineering application prospects in the field of hole-making for difficult-to-cut materials in aerospace. However, LFVAD technology still needs a more comprehensive understanding of its material removal process, especially the ploughing effect, in order to better match appropriate process parameters and tools. In this paper, through the comprehensive analysis of the ploughing effect in LFVAD, the ploughing effect condition model and ploughing volume model are established. The validity of the model is verified by LFVAD of titanium alloy (Ti) and aluminum alloy (Al) materials. The results indicate that the ploughing radius prediction error of established ploughing condition model is within 4.5%. The ploughing effect has a strong influence on the thrust force fluctuation, and the established ploughing volume model is verified based on the ploughing force. The prediction error of the maximum and minimum thrust force fluctuation in LFVAD of Ti is within 18.7%. More importantly, it is reliably explained that even if process parameters meet the chip breaking conditions, continuous ploughing action will still keep the tool and workpiece in constant contact, causing the minimum thrust force to be greater than zero and reducing the tool-workpiece separation effect. This will have a negative impact on chip breaking, drilling force, heat and tool wear, and a comprehensive understanding of the ploughing effect can provide a theoretical basis for solving these problems. This study can provide a reference for the industrial application of LFVAD technology.