Iranian Journal of Manufacturing Engineering

Iranian Journal of Manufacturing Engineering

Experimental investigation of tool wear and surface quality in ultrasonic-assisted drilling of grey cast iron

Document Type : Original Article

Authors
Aminollah Mohammadi
Mohammad Reza Dehghani
Abbas Ghaei
Department of Mechanical Engineering, Isfahan University of Technology, Isfahan, Iran
10.22034/ijme.2025.522954.2083
Abstract
Traditional drilling of hard and brittle materials, including grey cast iron, causes excessive tool wear and reduced drill life due to the presence of abrasive carbide and silicon particles in its structure, resulting in reduced hole accuracy and quality. This research aims to improve surface quality and increase drill life in drilling grey cast iron. Using advanced and modern methods in traditional machining processes can improve machining conditions. In this article, the effect of using ultrasonic vibrations on grey cast iron drilling has been studied. First, the design and analysis of the vibrating tool were carried out using Abaqus software, and after manufacturing the ultrasonic vibrating set, it was installed on the computer numerical control milling machine. Experimental results show that the use of ultrasonic waves has reduced tool wear by 30% and improved its life, while also increasing the quality of the hole surface by 20% and improving the roundness of the hole in gray cast iron drilling operations.
Keywords
Ultrasonic Drilling
Tool Wear
Surface Roughness
Roundness
Grey Cast Iron
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