High borosilicate glass, as a key aviation glass material, is widely used in aircraft windshields, canopies, and optical observation windows. However, its high hardness and brittleness easily cause serious edge chipping and surface damage in conventional drilling, which restricts the high-quality machining of micro-holes. To solve this engineering problem, this paper adopts longitudinal-torsional ultrasonic vibration-assisted micro-drilling (LT-UVD) as an innovative precision machining method, aiming to realize low-damage drilling of high borosilicate glass and reveal its process mechanism. Combining finite element simulation based on the JH-2 constitutive model and single-factor experiments, this study systematically investigates the effects of ultrasonic amplitude and spindle speed on the surface quality of hole entrance, including chipping size, spalling area, and crack morphology. The results show that longitudinal-torsional ultrasonic vibration (LT-UV) can significantly suppress hole entrance chipping, and the surface morphology is more regular with fewer cracks compared with conventional drilling (CD). Both ultrasonic amplitude and spindle speed present nonlinear regulatory effects and have optimal process windows; excessively low or high parameters will degrade machining quality. This research clarifies the suppression mechanism of LT-UV on crack propagation and brittle fracture, provides theoretical basis and process reference for high-quality, low-damage micro-drilling of hard and brittle aviation glass, and has important engineering application value for improving the performance and service life of aerospace optical components.
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