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CSME 2025/06
Volume 46 No.3
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307-315
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Use of Custom Macro Functions (CMFs) and Grey-Taguchi Method for Ultrasonic Vibration-Assisted Small Diameter Deep-Hole Drilling (SDDHD) of Ti-6Al-4V Alloy
Kang-Yu Liao a, Ting-Hsueh Chuang b, Chia-Ho Jiang c, Shao-Yu Wei c, Ming-Chang Wu d and Chung-Chen Tsao
aLecturer, Department of Mechanical Engineering, Lunghwa University of Science and Technology, Taoyuan, Taiwan 333326, ROC
bAssistant Professor, Department of Mechanical Engineering, Lunghwa University of Science and Technology, Taoyuan, Taiwan 333326, ROC
cGraduate student: Department of Mechanical Engineering, Lunghwa University of Science and Technology, Taoyuan, Taiwan 333326, ROC
dAssociate Professor, Department of Mechanical Engineering, Lunghwa University of Science and Technology, Taoyuan, Taiwan 333326, ROC.
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Abstract:
Small diameter deep-hole drilling (SDDHD) of Ti-6Al-4V alloy has become a subject of concern to many researchers due to its common shortcomings such as poor hole quality, high unit energy consumption, short tool life, and high processing cost. When writing processing codes for parts on CNC machine tools, using the custom macro function (CMF) can reduce the overall programming time and cost compared with CAD/CAM systems. For different process applications, many studies use non-traditional machining (NTM) to shorten the machining cycle of difficult-to-cut materials (DCM). Ultrasonic vibration-assisted machining (UVAM) is an effective method to achieve this goal. The Grey-Taguchi method is often used to solve the problems of multi-quality characteristics (MQCs) optimization. Therefore, this study combines CMFs, Grey-Taguchi method and UVAM to optimize the MQCs (thrust force (F) and surface roughness (R)) of SDDHD Ti-6Al-4V alloy. The experimental results show that specific processing parameters (spindle speed (A), feed rate (B), pecking-depth (C) and ultrasonic current (D)) have the significant effect on the optimal MQCs for ultrasonic vibration-assisted SDDHD in Ti-6Al-4V alloy. B and D are the most important processing parameters of MQC, with contribution rates (P) of 42.89% and 28.41%, respectively. Moreover, CMFs can obviously reduce CNC programming time for the 2nd and subsequent parts in SDDHD of Ti-6Al-4V alloy by 90% compared to CAD/CAM systems.
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Keywords: custom macro functions, ultrasonic vibration-assisted machining, small diameter deep-hole drilling, multi-quality characteristics, grey-Taguchi method.
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*Corresponding author; e-mail: aetcc@mail.lhu.edu.tw>
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©
2025
CSME , ISSN 0257-9731
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