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Acoustic Process Monitoring for Ultrasonic-assisted Deep Drilling

: Georgi, Oliver; Rüger, Carlo; Rentzsch, Hendrik; Hochmuth, Carsten; Putz, Matthias; Dix, Martin; Papsdorf, Günther

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Carletti, E. ; The International Institute of Acoustics and Vibration -IIAV-:
27th International Congress on Sound and Vibration, ICCSV 2021. Proceedings. Online resource : "Advances in Acoustics, Noise and Vibration - 2021", 11-16 July 2021, virtual
Gliwice: Silesian University Press, 2021
ISBN: 978-83-7880-799-5
8 pp.
International Congress on Sound and Vibration (ICCSV) <27, 2021, Online>
Conference Paper, Electronic Publication
Fraunhofer IWU ()
ultrasonic; Deep Drilling; tool condition monitoring; in-process measurement

Regarding deep drilling, problems in terms of chip formation and removal, burrs, tool vibrations as well as process reliability occur. Modern scientific approaches face these problems and aim to improve productivity, quality and reliability to reduce manufacturing costs. At the same time, there is a trend to use in-process monitoring and control in terms of adaptive machining processes in order to operate cutting processes close to the limits of stability. The application of ultrasonic assistance for drilling and deep drilling processes enables multiple advantages like reduced tool wear and burr formation as well as enhanced chip breaking behaviour. Moreover, ultrasound enables the use of previously unused physical effects to obtain information from the process zone and identify process conditions. In this context, the paper presents an approach of using modulation phenomena to evaluate dynamic process stability, using ultrasound as a carrier signal for low-frequency vibrations related to the deep drilling tool. In addition, the resonant coupling of ultrasonic system and cutting operation is used to draw direct conclusions about the load behaviour of the machining process from characteristics of the resonant vibration system. This directly leads to the possibility to perform in-process monitoring of tool wear. The article covers the theoretical basics, the hardware realization as well as experimental investigations regarding acoustic process monitoring for ultrasonic-assisted deep drilling.