Novel micro deep drilling using micro long flat drill with ultrasonic vibration

This paper highlights the development of micro long flat drills with nominal diameter and flute length of 20 μm and 200 μm, respectively, by precision grinding. Furthermore, it also covers the evaluation of the developed micro long flat drill in micro deep drilling. Micro long flat drills were made of ultra-fine grained cemented carbide containing WC particles with an average particle diameter of 90 nm. First, the study focused on establishing the optimal web thickness of micro long flat drill showing the best performance in micro deep drilling. In drilling experiment, observation was conducted with the aim of finding the best conditions and method of micro deep drilling into both duralumin and stainless steel workpieces. This observation included the applications of ultrasonic vibration (USV) and step feeding method. The study proved that there was an optimum web thickness resulting in the best drilling performance. Furthermore, the application of USV during drilling could lead to a longer tool life significantly. However, there was no improvement of drilling performance in drilling with step feeding.

► Micro long flat drills with a nominal diameter of 20 μm and a flute length of 200 μm was developed by precision grinding.
► Drilling performance to duralumin and stainless steel was conducted.
► The effects of web thickness, ultrasonic vibration and step feeding were observed.
► There was an optimum web thickness resulting to longer tool life.
► Ultrasonic vibration could increase the drilling performance of the developed tool.