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

Mohammadi, Aminollah; Dehghani, Mohammad Reza; Ghaei, Abbas

doi:10.22034/ijme.2025.522954.2083

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

Articles in Press

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

Subjects