Analysis of machining performance in ultrasonic-assisted drilling of Al6061 using a micro-textured drill bit: A validated finite element method
Journal of Manufacturing Processes, vol.170, pp.118-126, 2026 (SCI-Expanded, Scopus)
- Publication Type: Article / Article
- Volume: 170
- Publication Date: 2026
- Doi Number: 10.1016/j.jmapro.2026.05.013
- Journal Name: Journal of Manufacturing Processes
- Journal Indexes: Science Citation Index Expanded (SCI-EXPANDED), Scopus, ABI/INFORM, Compendex, INSPEC, Materials Science & Engineering Collection (ProQuest), Pharma Collection (ProQuest), Technology Collection (ProQuest)
- Page Numbers: pp.118-126
- Keywords: Finite element simulation, Machining process modeling, Micro-texture, Ultrasonic-assisted drilling
- Ondokuz Mayıs University Affiliated: Yes
Abstract
Ultrasonic-assisted drilling (UAD) combined with micro-textured drill bits is an effective approach to improve drilling performance by enhancing thermo-mechanical interactions at the tool–workpiece interface. This study develops and validates a finite element–based simulation framework to model UAD with different micro-texture geometries and to quantitatively predict thrust force, drill bit temperature, interface temperature, and chip formation. Three micro-texture designs are systematically compared to clarify the coupled effects of ultrasonic vibration and surface texturing on drilling behavior. The suggested finite element model is calibrated using randomly selected cutting conditions, achieving high prediction accuracy with absolute errors of 2.1% for thrust force and 0.1% for drill bit temperature. Simulation results demonstrate that the parallel micro-textured drill bit under UAD conditions delivers optimal performance, reducing thrust force by up to 39% while maintaining regulated thermal properties. The validated modeling approach demonstrates strong potential for predictive analysis and simulation-driven design of advanced drilling processes.