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<p>Bulk metallic glasses (BMGs) have wide applications in aerospace, automotive power, and healthcare, and have become a new material with broad application potential. High material removal rate and high-efficiency drilling are among the main processes for creating holes with high dimensional accuracy and high casting surface quality. Poor hole quality can lead to cracks and reduced reliability. To propose a machining process suitable for amorphous alloys and achieve better drilling quality, this paper focuses on the Zr-based bulk metallic glass Zr52Cu17.5Ti16Ni12Nb2.5 as the research object. The drilling characteristics of the bulk metallic glass are studied through a combination of experiments and simulations, finding that the trends of simulation and experimental results are consistent, though the difference is around 30%. When the feed rate f = 1.2&#xa0;mm/min, increasing the spindle speed reduces both axial force and torque. When the speed n is 5000 r/min, both axial force and torque increase with feed rate. By studying the effect of cutting parameters on drilling force during the machining of amorphous alloys, it is found that as the spindle speed increases from 4000 r/min to 10,000 r/min, the axial force Fz gradually decreases from the initial 47.16&#xa0;N to 27.09&#xa0;N, a reduction of 42.6%. The torque Mz gradually decreases from the initial 0.521&#xa0;N·m to 0.355&#xa0;N·m, a reduction of 31.9%. When the feed rate increases from 0.3&#xa0;mm/min to 2.1&#xa0;mm/min, the axial force gradually increases from the initial 33.62&#xa0;N to 55.48&#xa0;N, an increase of 65.0%, and the torque Mz gradually increases from the initial 0.394&#xa0;N·m to 0.523&#xa0;N·m, an increase of 32.7%. Through studying chip breakage and machined hole quality, it is found that as the spindle speed increases, the hole quality first improves and then deteriorates, with the highest quality achieved at a spindle speed of <i>n</i> = 5000 r/min. Both excessively high and low feed rate reduce hole quality, and the best hole quality at the exit is achieved at a feed rate of f = 1.2&#xa0;mm/min.</p>

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Simulation and experimental investigations into chip formation mechanism of drilling for Zr-based bulk metallic glass

  • 期刊论文

  • 发表日期：

    2025年12月1日

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  • Yongjie Gao,
  • Yin Liu,
  • Feng Kang,
  • Heran Yang,
  • Zhenjiang Li,
  • Zewei Yuan,
  • Sheng Qu,
  • Shibo Mu,
  • Hongxun Zhao,
  • Haosheng Dong

摘要

Bulk metallic glasses (BMGs) have wide applications in aerospace, automotive power, and healthcare, and have become a new material with broad application potential. High material removal rate and high-efficiency drilling are among the main processes for creating holes with high dimensional accuracy and high casting surface quality. Poor hole quality can lead to cracks and reduced reliability. To propose a machining process suitable for amorphous alloys and achieve better drilling quality, this paper focuses on the Zr-based bulk metallic glass Zr52Cu17.5Ti16Ni12Nb2.5 as the research object. The drilling characteristics of the bulk metallic glass are studied through a combination of experiments and simulations, finding that the trends of simulation and experimental results are consistent, though the difference is around 30%. When the feed rate f = 1.2 mm/min, increasing the spindle speed reduces both axial force and torque. When the speed n is 5000 r/min, both axial force and torque increase with feed rate. By studying the effect of cutting parameters on drilling force during the machining of amorphous alloys, it is found that as the spindle speed increases from 4000 r/min to 10,000 r/min, the axial force Fz gradually decreases from the initial 47.16 N to 27.09 N, a reduction of 42.6%. The torque Mz gradually decreases from the initial 0.521 N·m to 0.355 N·m, a reduction of 31.9%. When the feed rate increases from 0.3 mm/min to 2.1 mm/min, the axial force gradually increases from the initial 33.62 N to 55.48 N, an increase of 65.0%, and the torque Mz gradually increases from the initial 0.394 N·m to 0.523 N·m, an increase of 32.7%. Through studying chip breakage and machined hole quality, it is found that as the spindle speed increases, the hole quality first improves and then deteriorates, with the highest quality achieved at a spindle speed of n = 5000 r/min. Both excessively high and low feed rate reduce hole quality, and the best hole quality at the exit is achieved at a feed rate of f = 1.2 mm/min.