J Electroceram (2008) 20:187–192
DOI 10.1007/s10832-007-9132-4
Piezoelectric actuator design for ultrasonically assisted
deep hole drilling
C. Potthast & R. Eisseler & D. Klotz &
J. Wallaschek & U. Heisel
Received: 28 November 2006 / Accepted: 17 April 2007 / Published online: 4 May 2007
# Springer Science + Business Media, LLC 2007
Abstract From different chipping machining processes it is
known that a superposition of the cutting kinematics with
additional vibration energy increases material removal rate
and tool life. Concerning the deep drilling process in the
scope of smallest diameters from 0.9 to 6 mm insights to this
so called hybrid processes are still awaited. Preliminary
investigations indicated that here is high, so far unused
potential. The goal of current research is an increase in
effectiveness of the deep hole drilling process by superimposing additional vibration energy in ultrasonic frequency
range by means of a piezoelectric transducer and lowfrequency vibrations in the range of acoustic frequencies as
well. Positive effects can appear in a couple of areas, e.g.
achievable surface quality, feeding force, drilling torque,
shape and length of chips, feasibility of machining ceramic
materials and tool wear. This paper describes mainly the
ultrasound conform design of the vibration unit. Furthermore
issues of contactless energy transfer into a rotating tool and
model based design of piezoelectric transducers will be
addressed.
Keywords Deep hole drilling . Ultrasonically assisted
machining . Superimposed vibrations . Model based design
of piezoelectric transducers
C. Potthast (*) : J. Wallaschek
Heinz Nixdorf Institute, University of Paderborn,
33102 Paderborn, Germany
e-mail: potthast@hni.upb.de
R. Eisseler : D. Klotz : U. Heisel
Institute for Machine Tools, University of Stuttgart,
70174 Stuttgart, Germany
1 Introduction
Many technical products, for example fuel-injection systems, oilways and air ducts, demand the creation of deep
holes with small diameters. In creating holes with ratios of
length to diameter up to 200 the deep hole drilling process
is the only adopted technique. The tools used in deep
drilling, the so called gun drills, are carbide tools with one
cutting edge. Figure 1 shows a conventional gun drill. The
right part of the gun drill will be screwed at the spindle of
the machine tool. A borehole goes through the whole gun
drill, which pipelines the cooling lubricant with high
pressure towards the workpiece. Besides cooling the chip
transport out of the borehole is an important function of the
lubricant. As can be seen in Fig. 1 the drill has a continuous
corrugation for the purpose of chip transport. The coolantchip-mixture coming out of the tool is absorbed by the box
for boring chips.
A disadvantage of gun drills is their scrawny shape and
the susceptibility to fracture caused by the brittle carbide
cutting material. The main reason for drill breakage are
long and badly winded chips which are hard to transport
away. The higher the rate of feed is the longer and worse
winded chips are produced. Through this the drilling torque
raises vigorously and the drill can break easily. This is
meant to be the main productivity limitation of the deep
hole drilling process.
By superposition of ultrasonic vibrations it is expected
that shorter chips will be produced which can be transported away more easily. Because of the decreasing drilling
torque the rate of feed and therefore the productivity could
be raised significantly. This is especially valid in the case of
machining with tools of smallest diameters, which — as a
result of its shape — can be loaded stronger in the axial
direction than in the circumferential direction. This gives the
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J Electroceram (2008) 20:187–192
Fig. 1 Gun drill in the deep
hole drilling process [1]
possibility of a decisive increase in rate of feed without the
danger of tool damage as a result of too high drilling torque.
Altogether the following positive effects could be realized:
&
&
&
&
&
&
Better surface quality
Lower drilling torque
Smaller chips (prevention of tool breakage)
Better chip transportation away from the tool tip
Lower tool wear
Feasibility of machining ceramic material
2 Preliminary investigations
It has been demonstrated in pilot surveys that the process
limitations described above (low rate of feed) can be moved
significantly. Figure 2 shows exemplarily the results attained
with a conventional ultrasonic actuator normally used in the
field of plastics welding. In each case a gun drill with 2 mm
in diameter came into operation.
Further results from this simple setup indicate that by
superposition of vibrations the tool was loaded stronger in
axial direction than without additional vibrations (32 to
40 N instead of 25 to 30 N without ultrasound). In contrast
the drilling torque which finally could lead to drill breakage
was decreased enormously. Moreover the investigations
show that by the use of additional vibration energy shorter
chips are produced than in conventional deep hole drilling.
Consequently chip deadlocks with subsequent drill breakage could be avoided even when extreme process parameters are chosen. A positive effect was also visible in terms
of tool wear.
3 Project description
The previous simple investigations have the disadvantage
that the vibration amplitude could not be set exactly and
could not be varied either. Therefore in this project a robust
and flexible experimental setup is fabricated which allows
systematic variation of process parameters. The most
important parameters along with its ranges of variation are
listed in Table 1.
Figure 3 shows the experimental setup which will be
used in future investigations. A piezoelectric transducer is
clamped in its vibration node and mounted on an axle. The
right end of the axle is plugged into the spindle of the
machine tool. Located between transducer and spindle is a
contactless energy transmission composed of two copper
coils. Each coil is clamped in a ferrite pot core.
The left coil is connected with the transducer and rotates
together with the gun drill. The coil on the right is fed by a
Fig. 2 Effects of superimposed vibrations on wear, drilling torque and chip length
J Electroceram (2008) 20:187–192
Table 1 Process parameters and range of variation.
Process parameter
Range of variation
Cutting speed
Rate of feed
Pressure of lubricant
Drill diameter
Frequency
Max. vibration
amplitude at tool tip
Materials
60–160 m/min
100–400 mm/min
100–240 bar
(2.0 and) 5.0 mm
20 kHz
50 μm
Max. rotation speed
Carbon lead alloy, chromium
molybdenum alloy, aluminum alloy
25,500 min−1
high frequency generator, does not rotate and is hold by the
housing. The magnetic field transmits the energy through
the air gap to the transducer. The transducers’ horn has a
centre hole for accurately centred booster connection.
Besides the transformation of the mechanical vibration
amplitude the booster has the function of reception and
transmission the cooling lubricant.
4 Design of the piezoelectric transducer
Two different modelling approaches have been pursued for
transducer design. For the rough design an analytical rod
model was used. This type of model is also called transfer
matrix method [2]. The simple rod theory is well adequate
for approximation of vibration behaviour if the lateral
dimensions of the whole transducer are smaller than one
quarter of the wavelength in the frequency of interest. The
basic process of the transfer matrix method is: split the
transducer into elementary mechanical and piezoelectric rod
parts (see Fig. 4), which are homogeneous and geometrically simple, derive the transfer matrix for each rod part and
finally concatenate all matrix transfer functions to one
whole transfer matrix with respect to series or parallel
coupling of the single rod elements.
Fig. 3 Experimental setup
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For each block the analytical model allows the computation of the vibration velocity and force at the right side of
the block with respect to vibration velocity and force at its
left side. The transfer matrix relation for a mechanical block
can be written as
bv a
ba
F
bv
¼ Am b e
Fe
ð1Þ
b a are input velocity and force and bv e
Where bv a and F
b e are the corresponding output quantities, respectiveand F
ly. Am is a 2×2 transfer matrix, which is derived from the
analytical model:
1
A ¼
2
m
"
cos ðkm LÞ
jAEkm
Ω sin ðkm LÞ
jΩ
AEkm
sin ðkm LÞ
cos ðkm LÞ
#
ð2Þ
Where j is the imaginary number, Ω is the exciting
angular frequency, km is the wave number, L and A are
length and cross area of the considered block element and E
is Young’s modulus. For a piezoelectric block the transfer
matrix relation can be written as
2
3
2
3
bv a
bv e
4F
b a 5 ¼ Ap 4 F
b e5
bI
b
U
ð3Þ
b are electric current and voltage. For the
Where bI and U
3×3 transfer matrix Ap see [2]. The whole transfer matrix
relation of the transducer can be obtained by connecting
transfer matrices of the elementary blocks in terms of
interface conditions between two blocks. Creation and
solution of the transfer relation can be implemented in a
computer algebra program. Further details on this method
can be found in [2].
On principle the design parameters can be divided into
fixed, variable and vibrational parameters. To the fixed
design parameters belong the process parameters, i.e.
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Fig. 4 Mechanical scheme and four-pole description of rod and piezo element [2]
contact force, impedance of tool and workpiece as well as
environmental conditions. Variable design parameters include the transducer parameters, i.e. a tuned natural
frequency, a nodal position near the mounting and the
geometric dimensions. To the vibrational parameters belong
the distance between resonance and antiresonance frequency, transformation of vibration amplitudes, maximum strain
in the PZT, efficiency and phase minimum.
Fig. 5 CAD model and finite element model of the piezoelectric transducer
J Electroceram (2008) 20:187–192
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5 Two different wave length concepts
Fig. 6 Schematical illustration of vibration amplitudes along the
geometry
The rough transducer design with the matrix transfer
method is an iterative process of changing the geometry
and solving the corresponding equations until the important design parameters have the desired values. In this
specific design a frequency of 20 kHz, a nodal position as
close to the mounting as possible and a low amplitude
transformation were desired, since the influence of the
process needs further investigation in order to determine
the optimal transformation. Fundamentally the same
design procedure is also possible with the finite element
method but one calculation cycle (preprocessing, solution, postprocessing) takes much more time than one
cycle with the analytical rod model. According to
experience the finite element method gives more accurate
results. Hence the rod type model is first used to find a basic
geometry and afterwards a modal analysis of this geometry
is carried out using ANSYS [3]. Finally, only a few
subsequent modifications are necessary, for example
positional corrections of the bearing. Figure 5 shows the
CAD and the finite element model of the designed
piezoelectric transducer. The transducer has a length of
118 mm, the substrate material is steel, four hard PIC181
ceramic rings are prestressed by a screw. The actuator is
driven in resonance by means of a generator keeping zero
phase between current and voltage.
Because of the centre hole in the horn the transducer is a
little bit longer than necessary for obtaining the desired
resonance frequency of 20 kHz. The effective resonance
frequency (19.8 kHz) is therefore lower. The low transformation of the vibration amplitude makes the transducer
quite load insensitive.
Fig. 7 Waveform measurements of the two different
concepts
The vibrational design of longitudinal actuators bases upon
a synthesis approach which is well known in ultrasonic
technology since a long time. The basic component is a so
called 1/2 longitudinal vibrator, since the longitudinal mode
shape represents a half of a wavelength. A longer actuator
with the same frequency can be achieved by stringing
together multiple 1/2 vibrators.
The low amplitude transformation of the transducer
makes it necessary to find solutions for higher mechanical
amplitudes at the gun drill tip. Since the booster has the
function of receiving the cooling lubricant in its vibration
node the middle of the booster is unavailable for constructing a transforming step. The achievable amplitude transformation with the designated booster (Fig. 3) is therefore
limited. Besides the alternative to arrange a second booster,
application of the 31/4-concept [4] comes into consideration. The 31/4-concept is a not very common approach but
it leads to high vibration amplitudes if the 1/4 part is thin
compared to the 1/2 parts. Figure 6 shows schematically the
vibration amplitudes in axial direction for classical 1/2concept and for the 31/4-concept.
Measurements with a laser vibrometer (Fig. 7) evidence
that this wave concept permits very high vibration
amplitudes at the tool tip. However, at the junction between
booster and carbide drill relatively high strain values occur
why the drill is at risk to break at this location. Experiments
will show how much amplitude is bearable.
Statements on the load sensitivity of the 31/4-concept
cannot be made up to now. It is expected that load sensitivity
is better than it would be with equivalent transformation with
boosters.
6 Conclusion
This paper describes the setup constructed for vibration
superimposed drilling in metal materials. The load insensitive piezoelectric transducer is designed with low amplitude
transformation in order to stay flexible for adjusting the
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desired amplitude with boosters or with the described 31/4concept. The energy is transmitted contactless into the
rotating transducer. The modified electrical behaviour can
be adjusted via two capacities, one arranged in series and
one in parallel. Right now the setup is near completion.
Experimental results will be published in near future.
Acknowledgements Thanks belong to the German Research Council (DFG) for funding this research project as grant no. WA 564/10-1.
J Electroceram (2008) 20:187–192
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3. ANSYS User’s Manual for Revision 10.0, A Commercial FiniteElement Software Package
4. P.E. Vasiliev, V.F. Kazantsev, L.L. Karmanov, Stab-Ultraschallschwinger,
Patent specification DE2914434C2, (1986) (in german)