Seminar Journal

Journal of Advanced Mechanical Design, Vol. 5, No.
2, 2011
Systems, and
Manufacturing
Attempt to Increase Step Feed by Adding
Ultrasonic Vibrations in Micro Deep Drilling*
Yohei NAMBU**, Kazuhiro OCHIAI**, Kenichiro HORIO***, Junichi KANEKO***,
Takeshi WATANABE**** and Shinichi MATSUDA*****
**Saitama Industrial Technology Center,
3-12-18 Kamiaoki, Kawaguhi, Saitama, 333-0844, Japan
E-mail: ynanbu@saitec.pref.saitama.jp
***Saitama University,
255 Shimo-Okubo, Sakura, Saitama, Saitama, 338-8570, Japan
****Nippon Nozzle Seiki Co.,Ltd,
5-17-1 Sakurada, Kuki, Saitama, 340-0203, Japan
*****Matsuda Engineering Management Laboratory,
4-326-4 Mihashi, Omiya, Saitama, Saitama, 330-0856, Japan
Abstract
In high aspect ratio micro deep drilling, to shorten the machining time while
maintaining the tool life, the addition of ultrasonic vibrations to increase the step
feed was examined. First, machining experiments with L/D=10 were conducted,
and an increase in the step feed upon the addition of ultrasonic vibrations was
confirmed by evaluation of the cutting force and tool wear. Furthermore, micro
deep drilling with a high aspect ratio of L/D=20 was examined. Our results reveal
that reducing the cutting speed and adding ultrasonic vibrations shorten the
machining time by increasing the step feed while maintaining a long tool life.
Moreover, we confirmed that the developed technique is effective for the micro
deep drilling of holes with a small diameter of 0.1 mm and L/D=15.
Key words: High Aspect Ratio, Step Feed, Microdrill, Ultrasonic Vibraiton
1. Introduction
In recent years, the miniaturization of nozzles in gas turbines for thermal power stations
or in marine diesel engines has been required to cope with the technological innovations of
high-pressure fuel injection(1). Therefore, it is considered that the diameter of future holes in
nozzles must be reduced to 0.2 mm or below from the current value of 1.0 mm. The aim of
the present study is to practically machine stainless-steel nozzles with micro deep holes
having a diameter of 0.2 mm or below and an aspect ratio (L/D) of 20 or above. From the
viewpoint of considering practical utility, the machining efficiency must be improved and
the machining time must be reduced.
In this report, to shorten the machining time while maintaining the tool life, the addition
of ultrasonic vibrations to increase the step feed was examined.
2. Problems in Micro Deep Drilling
In micro deep drilling, it is difficult for cutting fluid to reach the cutting point, heat
cannot easily be dissipated, and the cutting edge tends to have a high temperature.
Furthermore, since the size of the flute with respect to the diameter of the drill is small for a
*Received 14 Mar., 2011 (No. 11-0202)
[DOI: 10.1299/jamdsm.5.129]
drill having a regular diameter, it is difficult to smoothly dispose the chips. These tendencies
Copyright © 2011 by JSME become more prominent as the aspect ratio increases(2).
129
Journal of Advanced Mechanical Design, Vol. 5, No. 2, 2011
Systems, and
Manufacturing
Thus, in micro deep drilling, such step feeding as depicted in Figure 1 is conducted to
cool the cutting edge and dispose the chips. However, since the step feed must be greatly
reduced in a micro deep hole with a large aspect ratio, the number of steps increases, and
the non cutting time devoted to reciprocating the rapid feed is increased. Therefore, a
serious practical problem, i.e., a marked increase in machining time, arises. As a typical
example of conducting micro drilling to obtain a hole with a diameter of 0.2 mm, Figure 2
shows the relationship between the step feed and the machining time of a single hole when
performing drilling to obtain a hole with a depth of 4 mm at a rapid feed speed of 200
mm/min and cutting feed speeds of 10 to 40 mm/min. The machining time decreases rapidly
as the step feed increases.
Effects such as a reduction in the cutting force due to the addition of ultrasonic
vibrations in micro drilling have been reported(3)～(8). The authors have suggested conditions
that extend tool life upon adding ultrasonic vibrations when drilling a hole of diameter 0.2
mm or below with an L/D of 20 or above (9).
In this report, the effect of an increase in the step feed by adding ultrasonic vibrations to
improve the machining efficiency is examined. First, machining experiments with L/D=10
were conducted, and the effect of an increase in the step feed obtained by the addition of
ultrasonic vibrations was confirmed by evaluation of the cutting force and tool wear.
Furthermore, on the basis of our experimental results, micro deep drilling with a high aspect
ratio of L/D=20 was examined. Moreover, it was confirmed that the developed technique is
effective for the micro deep drilling of holes with a small diameter of 0.1 mm and L/D=15.
Rapid feed
・・・・・
Cutting feed
Step feed
Fig. 1 Step feed drilling
400
Cutting feed speed
350 10mm/min
20mm/min
Machining time(1 hole) s
300 40mm/min
250
200
150
100
50
0
0 0.05 0.1 0.15 0.2
Step feed mm
Fig. 2 Relationships between step feed and machining time
130
Systems, and
Manufacturing
3. Experimental Equipment
Figure 3 is a schematic diagram of the experimental setup. We used a high-speed
machining center with an ultrasonic spindle having an ultrasonic frequency of 40 kHz
attached to the spindle box of the machining center. Furthermore, austenitic stainless steel
was used as the work material, and an ultrafine-grained cemented carbide drill was adopted
as the tool. Table 1 shows the tool specifications. Experiments were conducted involving
measurement of the cutting force in the thrust direction using a dynamometer, observation
of the tool wear using a scanning electron microscope (SEM), and evaluation of the tool
life.
Vibration
spindle
Controller
F,A Drill
Data
Workpiece recorder
Dynamometer(thrust force)
Bed
Fig. 3 Experimental setup
Table 1 Tool geometry
Drill diameter mm 0.2

Drill type HAM Japan, HAM382
Point angle deg 140
Flute length mm 4.8
Thinning Non thinning
Material Cemented carbide
Grain size nm 600
Coating Non coating
4. Micro Deep Drilling (L/D=10)

To examine the effect of adding ultrasonic vibrations to the micro deep drilling of holes
with a normal depth, a through hole with a diameter of 0.2 mm and a depth of 2 mm
(L/D=10) was drilled with the drilling conditions given in Table 2. Comparisons were made
of the thrust force, the tool wear after drilling ten holes, and the tool life for different step
feeds.
Table 2 Drilling conditions
Workpiece Stainless steel (JIS SUS304)

-1
Spindle speed min 5000
Feed speed mm/min 10
Hole depth mm 2 , 4 (Through)
Step feed mm 0.025~0.4
Feed per tooth μm/tooth 1.0
Vibration frequency kHz 40
Vibration amplitude μm (p-p) 3
Coolant Water-soluble
131
Systems, and
Manufacturing
Drilling was carried out while varying the step feed Q from 0.025 to 0.4 mm with an
ultrasonic amplitude of 3 μm. Figure 4 shows the effect of adding ultrasonic vibrations. The
abscissa represents the number of holes drilled, and the ordinate represents the thrust force.
The thrust force was decreased by the addition of vibrations, and the increment in thrust
force was also reduced as drilling proceeded.
14
L/D=10
12
10
Thrust force N
8
4 Q0.025mm (Without vibration)

Q0.1mm (Without vibration)
2 Q0.025mm (With vibration)
Q0.1mm (With vibration)
0
0 2 4 6 8 10 12
Number of holes
Fig. 4 Effect of vibration on thrust force (1st hole – 10th hole)
Figure 5 shows the results obtained for the thrust force while drilling the 10th hole. This
figure shows the effect of the step feed on the thrust force in an understandable manner. In
the case of drilling using no additional vibrations, the thrust force increased with the step
feed, and breakage occurred at a step feed of 0.2 mm or above before drilling the 10th hole.
In vibration drilling, the thrust force hardly changed even though the step feed was
increased.
14
L/D=10
12
10
Thrust force N
2 Without vibration
With vibration
0
0 0.1 0.2 0.3 0.4 0.5
Step feed mm
Fig. 5 Relationships between step feed and thrust force [10th hole]
Figure 6 shows an SEM image of the cutting edge after drilling ten holes. Abrasive
wear occurred on the flank face of the cutting edge both with and without ultrasonic
vibrations. Tool wear was reduced by adding the vibrations, and that was quantitatively
evaluated to be flank wear at the center of the main cutting edge. Figure 7 shows the
relationship between the step feed and tool wear after drilling ten holes. Similarly to the
results for the thrust force depicted in Figure 5, in vibration drilling, the tool wear remained
almost the same even though the step feed was increased. The contact time between the
drill and the workpiece per step increases when the step feed is increased. Therefore, it can
be considered that for conventional (no vibration) drilling, the cutting temperature increases
during drilling, accelerating tool wear. On the other hand, the cutting temperature does not
greatly increase during vibration drilling since the ultrasonic vibrations have a cooling
effect.
132
Systems, and
Manufacturing
Figure 8 shows the results of investigating the tool life. The ordinate represents the
number of holes drilled attained before the breakage of the drill occurred. First, in
conventional drilling, a comparison between step feeds of 0.025 mm and 0.1 mm was made.
The tool life when the step feed was 0.1 mm was approximately half that when the step feed
was 0.025 mm. Thus, increasing the step feed leads to an increase in tool wear in
conventional drilling. Subsequently, a comparison between conventional drilling and
vibration drilling was made with a step feed of 0.1 mm. The tendency of tool wears depicted
in Figure 7 was observed, and the tool life in vibration drilling was approximately seven
times that in conventional drilling. These results confirm that adding ultrasonic vibrations in
micro deep drilling with L/D=10 results in an increase in the step feed and a reduced
machining time.
Tool wear Tool wear
50μm 50μm
(a) Without Vibration (b) With vibration

Fig. 6 SEM photograph of drill [after 10 holes]
20
L/D=10 Without vibration
With vibration
15
Tool wear μm
10
0
0 0.1 0.2 0.3 0.4 0.5
Step feed mm
Fig. 7 Relationships between step feed and tool wear [after 10 holes]
800
L/D=10
attained till a breakage of the tool
700
Without vibration
600 With vibration
Drilling numbers
500
400
300
200
100
0
Step feed Step feed Step feed
0.025mm 0.1mm 0.1mm
Fig. 8 Effect of vibration and step feed on tool life (L/D=10)
133
Systems, and
Manufacturing
5. High Aspect Ratio Micro Deep Drilling (L/D=20)
5.1 Effect of Ultrasonic Vibrations
To examine the effect of ultrasonic vibrations on the drilling of micro deep holes with a
high aspect ratio, through holes with a diameter of 0.2 mm and a thickness of 4 mm
(L/D=20) were drilled. The thrust force and tool wear were compared after drilling ten holes
with different step feeds.
Figure 9 shows the transition of the thrust force, and Figure 10 shows the relationship
between the step feed and the thrust force for the 10th hole. In micro deep drilling with a
high aspect ratio of L/D=20, the thrust force increased with the step feed, even in vibration
drilling, and breakage occurred before the 10th hole was drilled when the step feed was 0.2
mm or above.
14
L/D=20 5000min-1
12
10
Thrust force N

0
0 2 4 6 8 10 12
Number of holes
14
L/D=20 5000min-1
12
10
Thrust force N
Without vibration
2
With vibration
0
0 0.1 0.2 0.3 0.4 0.5
Step feed mm
Fig. 10 Relationships between step feed and thrust force [10 th hole]
Figure 11 shows the relationship between the step feed and tool wear after drilling the
ten holes. Similarly to the results for the thrust force depicted in Figure 9, tool wear
increased with the step feed even in vibration drilling. These results reveal that increasing
the step feed is difficult in micro deep drilling with L/D=20 even when ultrasonic vibrations
are added. Thus, it is difficult to supply a cutting fluid when the depth of a hole increases,
thereby deteriorating the cooling effect of the vibration.
134
Systems, and
Manufacturing
20
5000min-1 With vibration
15
Tool wear μm
10
0
0 0.1 0.2 0.3 0.4 0.5
Step feed mm
5.2 Examining the Cutting Speed

To reduce the cutting temperature, a cutting speed that greatly reduces the cutting
temperature was searched for. Here, the spindle speed was varied from 1000 min-1 to 5000
min-1 and the step feed was fixed at 0.1 mm. Figure 12 shows the relationship between the
spindle speed and the tool life. The tool life is short at all spindle speeds in conventional
drilling, but it is greatly increased when the cutting speed is reduced in vibration drilling.
These results confirm that the effect of ultrasonic vibrations can be obtained.
60
50 With vibration
40
Drilling numbers
30
20
10
0
1000 2000 3000 4000 5000
Spindle speed min-1
Fig. 12 Effect of vibration and spindle speed on tool life
We next compared the thrust force and tool wear after drilling ten holes while varying
the step feed and fixing the spindle speed at 2000 min-1 that can acquire better effect of the
ultrasonic vibrations was selected. Figure 13 shows the transition of the thrust force, and
Figure 14 shows the relationship between the step feed and the thrust force for the 10th
hole. Compared with the results in Figure 10, when reducing the cutting speed in vibration
drilling, the thrust force does not increase as much, even when increasing the step feed.
Figure 15 shows the relationship between the step feed and tool wear after drilling ten
holes. For micro deep drilling with L/D=20, it is revealed that reducing the cutting speed
suppresses the tool wear caused by increasing the step feed.
It has been discovered that to drill a micro deep hole having a large aspect ratio with a
large step feed, reducing the cutting speed and adding ultrasonic vibrations are effective.
The machining time provided when the cutting speed is reduced will be evaluated in the
following chapter.
135
Systems, and
Manufacturing
14
L/D=20 2000min-1
12
10
Thrust force N
8

0
0 2 4 6 8 10 12
Number of holes
14
L/D=20 2000min-1
12
10
Thrust force N
Without vibration
2
With vibration
0
0 0.1 0.2 0.3 0.4 0.5
Step feed mm
Fig. 14 Relationships between step feed and thrust force [10 th hole]
20
L/D=20
5000min-1 Without vibration
15
2000min-1 Without vibration
Tool wear μm
10
0
0 0.1 0.2 0.3 0.4 0.5
Step feed mm
6. Application to Micro Deep Holes having a Diameter of 0.1 mm

To examine the application of ultrasonic vibrations in the drilling of micro deep holes
with a smaller diameter, a through hole with a diameter of 0.1 mm and a thickness of 1.5
mm (L/D=15) was drilled. The total machining time and tool life were compared for
different step feeds and spindle speeds.
136
Systems, and
Manufacturing
Figure 16 shows the relationship between the step feed and the total machining time
per through hole for different spindle speeds. Here, the cutting feed speed was set so that
the feed per tooth was 1 μm. In conventional drilling, the typical step feed is approximately
0.01 mm. Thus, even if the spindle speed is decreased in ultrasonic vibration drilling, the
machining time can be greatly reduced by increasing the step feed.
250
-1
3000min-1
-1
4000min-1
200 5000min-1
-1
Machining time(1 hole) s

150
100
50
0
0 0.05 0.1
Step feed mm
Fig. 16 Relationships between step feed and machining time
To consider the practical machining time, drilling experiments were performed with the
step feed varied from 0.05 mm to 0.1 mm. Figure 17 shows the relationship between the
step feed and the tool life for different spindle speeds and with and without ultrasonic
vibrations. When the step feed was 0.05 mm, which is larger than conventional values, the
addition of ultrasonic vibrations greatly increased the tool life irrespective of the spindle
speed. When the step feed was further increased to 0.1 mm, reducing the spindle speed, i.e.,
the cutting speed, a greater effect of the ultrasonic vibrations was obtained and the tool life
was prolonged.
Our results reveal that reducing the cutting speed and adding ultrasonic vibrations can
increase the step feed and shorten the machining time while maintaining a long tool life.
120
5000min-1
-1 Without vibration 5000min-1
-1 With vibration
4000min-1
-1 With vibration
3000min-1
-1 With vibration
100
Drilling numbers
80
60
40
20
0
0 0.05 0.1
Step feed mm
7. Conclusion
In micro deep drilling, to shorten the machining time while maintaining the tool life, the
addition of ultrasonic vibrations to increase the step feed was examined.
(1) Machining experiments with L/D=10 were conducted, and an increase in the step feed
upon the addition of ultrasonic vibrations was confirmed by evaluation of the cutting
force and tool wear.
137
Systems, and
Manufacturing
(2) On the basis of above result, micro deep drilling with a high aspect ratio of L/D=20
was examined. The effect of adding ultrasonic vibrations was less marked than that
when L/D=10.
(3) We attempted to suppress the increase in cutting temperature by reducing the cutting
speed. As a result, we discovered that ultrasonic vibrations can be applied to the micro
deep drilling of holes with a high aspect ratio of L/D=20.
(4) We confirmed that the developed technique is effective for drilling micro deep holes
with a small diameter of 0.1 mm and L/D=15.
Our results revealed that reducing the cutting speed and adding ultrasonic vibrations
can shorten the machining time by increasing the step feed while maintaining a long tool
life.
References
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Firing Durl Fuel, Mitsubishi Heavy Industries, Ltd. Technical Review, Vol.36, No.3 (1999),
pp. 70-74
(2) Nambu, Y., Ochiai, K., Akiba, D., Nagakubo, T., Matsuda, S., High-Aspect-Ratio
Microdrilling of Cobalt-Based Superalloy, Journal of the Japan Society for Precision
Engineering (in Japanese), Vol.75, No.9 (2009), pp. 1083-1087
(3) Onikura, H., Ohnishi, O., Drilling Mechanisms in Ultrasonic-Vibration Assisted
Microdrilling, Journal of the Japan Society for Precision Engineering (in Japanese),
Vol.64, No.11 (1998), pp. 1633-1637
(4) Ohnishi, O., Onikura, H., Hata, A., Yamamoto, K., Fabrication of Micro Flat Drills by
Precision Grinding and Drilling into Duralumin and Stainless Steel with Ultrasonic
Vibration, JSME international journal. Series C, Mechanical systems, machine elements
and manufacturing, Vol.47, No.1 (2004), pp. 117-122
(5) Ohnishi, O., Onikura, H., Effects of Ultrasonic Vibration on Microdrilling into Inclined
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No.9 (2003), pp. 1337-1341
(6) Harada, K.，Sasahara, H. , Cutting Mechanism on Ultrasonic Vibration Cutting (3rd
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No.8 (2005), pp. 1005-1009
(7) Tanaka, S.，Takagi, J., Yokosawa, T., Study on ultrasonic machining of small diameter
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(8) Moriwaki, T., Shamoto, E., Ultraprecision Diamond Turning of Stainless Steel by Applying
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(9) Nambu, Y., Ochiai, K., Horio, K., Kaneko, J., Watanabe, T., Matsuda, S., High-Aspect-Ratio
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138

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Journal of Advanced Mechanical Design, Vol. 5, No.

Fig. 1 Step feed drilling

Fig. 3 Experimental setup

Table 1 Tool geometry

Drill diameter mm 0.2

4. Micro Deep Drilling (L/D=10)

Workpiece Stainless steel (JIS SUS304)

4 Q0.025mm (Without vibration)

(a) Without Vibration (b) With vibration

4 Q0.025mm (Without vibration)

5.2 Examining the Cutting Speed

4 Q0.025mm (Without vibration)

6. Application to Micro Deep Holes having a Diameter of 0.1 mm

Machining time(1 hole) s

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