Surface Integrity of Ultrasonic Assisted Drilling Soft Magnetic Alloy 1J22

doi:10.3901/JME.2025.01.345

Abstract

Abstract: As the performance requirements of electromagnetic components gradually increase, 1J22 soft magnetic alloy has attracted extensive interest due to its high saturation magnetic induction strength, high saturation magnetostriction coefficient and high Curie temperature. Consequently, this alloy is regarded as a material capable of significantly improving the performance of electromagnetic components in the aerospace. However, the machinability of 1J22 soft magnetic alloy is poor. The surface integrity of the components after drilling will seriously affect the magnetic field uniformity and service stability, which seriously hinders its application. Ultrasonic assisted drilling technology is used in order to solve the hole-making problem of 1J22 soft magnetic alloy. Combining experimental testing with finite element method, the surface integrity was characterized using optical microscopy, scanning electron microscopy, transmission electron microscopy, and microhardness tester. The effects of ultrasonic vibration and drilling parameters on the surface morphology, roughness, microstructure, hardening degree, and edge quality of 1J22 soft magnetic alloy holes were concluded and the in fluence mechanism of ultrasonic vibration was revealed. It is found that, compared to conventional drilling, the applying of ultrasonic assisted drilling can decrease the surface roughness by 21%. The ultrasonic assisted drilling can also facilitate the separation of chips and hole wall area, reducing plastic deformation in the hole wall region and minimizing the affected area of microstructural changes. Specifically, after ultrasonic assisted drilling, there is a 40% reduction in grain refinement layer width and a 6% decrease in the depth of the work-hardened layer. On the contrary, the higher instantaneous axial force can lead to an increase in the area of edge chipping at the hole exit. The research provides theoretical guidance for the machining of high surface integrity holes in 1J22 soft magnetic alloy.

Key words: soft magnetic alloy 1J22, ultrasonic assisted drilling, surface integrity, surface morphology and roughness, micro-structure, work hardening, exit chipping, finite element method

CLC Number:

TG527

WEI Yuxin, SONG Hongxia, ZHANG Yuan, XUE Guanming, KANG Renke, BAO Yan, DONG Zhigang. Surface Integrity of Ultrasonic Assisted Drilling Soft Magnetic Alloy 1J22[J]. Journal of Mechanical Engineering, 2025, 61(1): 345-359.

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