A Mechanistic Approach to the Prediction of Material Removal Rates in Rotary Ultrasonic Machining

1995 ◽  
Vol 117 (2) ◽  
pp. 142-151 ◽  
Author(s):  
Z. J. Pei ◽  
D. Prabhakar ◽  
P. M. Ferreira ◽  
M. Haselkorn
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Diamond Particle ◽  
Machining Parameters ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Stabilized Zirconia ◽  
Mechanistic Approach ◽  
Wide Range

An approach to modeling the material removal rate (MRR) during rotary ultrasonic machining (RUM) of ceramics is proposed and applied to predicting the MRR for the case of magnesia stabilized zirconia. The model, a first attempt at predicting the MRR in RUM, is based on the assumption that brittle fracture is the primary mechanism of material removal. To justify this assumption, a model parameter (which models the ratio of the fractured volume to the indented volume of a single diamond particle) is shown to be invariant for most machining conditions. The model is mechanistic in the sense that this parameter can be observed experimentally from a few experiments for a particular material and then used in prediction of MRR over a wide range of process parameters. This is demonstrated for magnesia stabilized zirconia, where very good predictions are obtained using an estimate of this single parameter. On the basis of this model, relations between the material removal rate and the controllable machining parameters are deduced. These relationships agree well with the trends observed by experimental observations made by other investigators.

Support Vector Fuzzy Adaptive Network in the Modeling of Material Removal Rate in Rotary Ultrasonic Machining

2008 ◽  
Vol 130 (4) ◽  
Author(s):  
Judong Shen ◽  
Z. J. Pei ◽  
E. S. Lee
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Support Vector ◽  
Adaptive Networks ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Adaptive Network ◽  
Fuzzy Adaptive

Rotary ultrasonic machining (RUM) is one of the cost-effective machining methods for machining difficult to process material. It is a hybrid machining process that combines the material removal mechanisms of diamond grinding with ultrasonic machining. However, due to the lack of understanding of the mechanisms of these operations, models for these machining processes are difficult to establish. In this paper, the support vector fuzzy adaptive network (SVFAN), a parameter free nonlinear regression technique, is used to model the material removal rate in RUM. The SVFAN retains the advantages of both the fuzzy adaptive networks and the support vector machines. The former possesses the linguistic representation ability and the latter is a very effective learning machine. The results are compared with that obtained by the use of fuzzy adaptive network and it is shown that the combined approach is a more effective algorithm for the modeling of complex manufacturing processes.

An experimental study on rotary ultrasonic machining of Macor ceramic

2016 ◽  
Vol 232 (7) ◽  
pp. 1221-1234 ◽  
Author(s):  
Ravi Pratap Singh ◽  
Sandeep Singhal
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Ultrasonic Power ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Desirability Approach ◽  
Index Value ◽  
The Impact ◽  
Desirability Index

Macor ceramic has been well recognized as an eminent engineering material which possesses enlarged industrial usage owing to its excellent and versatile properties. However, its fruitful and economic processing is still unanswered. This article has targeted to experimentally investigate the influence of numerous process variables on machining characteristics in rotary ultrasonic machining of Macor ceramic. The impact of different input factors, namely, spindle speed, feed rate, coolant pressure, and ultrasonic power has been appraised on process responses of interest, that is, material removal rate and chipping size. The experimental plan was designed by employing response surface methodology through central composite rotatable design. The variance analysis test has also been performed with a view to observe the significance of considered parameters. Microstructure of machined samples has also been evaluated and analyzed using scanning electron microscope. This analysis has revealed and confirmed the presence of dominated brittle fracture that caused removal of material along with the thin plastic deformation in rotary ultrasonic machining of Macor ceramic. The reliability and competence of the developed mathematical model have been established with test results. The multi-response optimization of machining responses has also been done by utilizing desirability approach, and at optimized parametric setting, the obtained experimental values for material removal rate and chipping size are 0.4762 mm3/s and 0.3718 mm, respectively, with the combined desirability index value of 0.937.

Optimization of material removal rate in ultrasonic machining of polycarbonate bulletproof glass and acrylic heat-resistant glass by Taguchi method

2017 ◽  
Vol 13 (4) ◽  
pp. 612-627 ◽  
Author(s):  
Kanwal Jeet Singh ◽  
Inderpreet Singh Ahuja ◽  
Jathinder Kapoor
Keyword(s):  
Taguchi Method ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Basic Knowledge ◽  
Machining Parameters ◽  
Ultrasonic Machining ◽  
Content Type ◽  
Heat Resistant ◽  
Percent Contribution

Purpose The purpose of this paper, an original research paper, is to study the optimization of material removal rate (MRR) in ultrasonic machining of polycarbonate bulletproof glass and acrylic heat-resistant glass. The machining of these materials is a very tough job. There are so many constraints which need to be taken into account while machining, but without proper knowledge of material properties and machining parameters, machining is not possible. This paper gives basic knowledge about polycarbonate bulletproof and acrylic heat-resistant glass and provides ways as to how these types of materials are processed or machined. Design/methodology/approach The Taguchi method was utilized to optimize the ultrasonic machining parameters for drilling these advanced materials. The relationship between MRR and other controllable process parameters such as concentration of slurry, type of abrasive, abrasive grit size, power rating, concentration of HF acid and type of tool material has been analyzed by using the Taguchi approach. Findings Through the Taguchi analysis, it is concluded that types of abrasive and HF acid concentrations have a significant role to play in MRR for both materials; in which, type of abrasive have 72.91 and 72.96 percent contribution in MRR for polycarbonate bulletproof and acrylic heat-resistant glass, respectively. Similarly, HF acid concentration has 14.70 and 14.65 percent contribution in MRR for polycarbonate bulletproof and acrylic heat-resistant glass, respectively. The MRR was improved by 34.44 percent in polycarbonate bulletproof glass and 29.25 percent in acrylic heat-resistant glass. Originality/value After experimental investigation, the results of the Taguchi modal are validated.

Experimental investigation of machining characteristics in rotary ultrasonic machining of quartz ceramic

2016 ◽  
Vol 232 (10) ◽  
pp. 870-889 ◽  
Author(s):  
Ravi Pratap Singh ◽  
Sandeep Singhal
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Quartz Ceramic ◽  
Ultrasonic Power ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Desirability Approach ◽  
Desirability Index ◽  
Machining Characteristics

Quartz ceramic has been well observed as one of the highly demanded advanced ceramics which is receiving enlarging industrial approbation owing to its excellent and superior properties. However, its fruitful processing with traditional and non-traditional machining methods is still a challenge. The current article has aimed to experimentally investigate the influence of several process variables, namely, spindle speed, feed rate, coolant pressure, and ultrasonic power on machining characteristics of interest, i.e. chipping size, and material removal rate in rotary ultrasonic machining of quartz ceramic. Response surface methodology has been employed to design the experiments and the variance analysis test has also been performed with a view to observe the significance of considered parameters. Microstructure of machined samples has also been evaluated and analyzed using scanning electron microscope. This analysis has revealed and confirmed the presence of dominating brittle fracture that caused removal of material along with the slighter plastic deformation in rotary ultrasonic machining of quartz ceramic. The soundness and competence of the developed mathematical model have been established with test results. The multi-response optimization of machining responses has also been done by utilizing desirability approach, and at optimized parametric setting, the obtained experimental values for material removal rate and chipping size are, 0.6437 mm3/s and 1.3326 mm, respectively, with the combined desirability index value of 0.949.

Analysis of the Material Removal Rate of Micro-Hole Machining of Ceramic Materials

2011 ◽  
Vol 347-353 ◽  
pp. 1572-1575 ◽  
Author(s):  
Shu Lung Wang ◽  
Ting Yu Chueh
Keyword(s):  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Rotation Speed ◽  
Removal Rate ◽  
Tool Geometry ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Related Factors ◽  
Drill Diameter

This study discussed what rotary ultrasonic machining (RUM) and tool geometry parameters combination can obtain bigger material removal rate (MRR) in drilling. The experimental configuration of this study was planned using Taguchi orthogonal array, where the drill diameter, rotation speed, power and feed rate were taken as the experimental factors. A relation model among the MRR and standard deviation of the holes walls and processing parameters and tool geometry was established, so as to achieve maximum MRR of the overall deep holes walls. The experimental results proved that application of the optimized parameters combination in rotary ultrasonic machining of holes processing can obtain bigger and better removal rate of holes walls. The effect of control factors on the holes quality was discussed from the straightness deviation and maximum material removal rate of related factors on the holes when the Taguchi method was used in rotary ultrasonic machining of holes drilling. The results showed that rotation speed, power, and feed rate under bigger level have a larger MRR than that of other level in a fixed drill diameter.

Modeling of Material Removal Mechanism in Micro Electric Discharge Milling of Ti-6Al-4V

2014 ◽  
Vol 592-594 ◽  
pp. 516-520 ◽  
Author(s):  
Basil Kuriachen ◽  
Jose Mathew
Keyword(s):  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Milling Process ◽  
Work Piece ◽  
Machining Parameters ◽  
Removal Mechanism ◽  
Material Removal Mechanism ◽  
Electric Discharge Milling

Micro EDM milling process is accruing a lot of importance in micro fabrication of difficult to machine materials. Any complex shape can be generated with the help of the controlled cylindrical tool in the pre determined path. Due to the complex material removal mechanism on the tool and the work piece, a detailed parametric study is required. In this study, the influence of various process parameters on material removal mechanism is investigated. Experiments were planned as per Response Surface Methodology (RSM) – Box Behnken design and performed under different cutting conditions of gap voltage, capacitance, electrode rotation speed and feed rate. Analysis of variance (ANOVA) was employed to identify the level of importance of machining parameters on the material removal rate. Maximum material removal rate was obtained at Voltage (115V), Capacitance (0.4μF), Electrode rotational Speed (1000rpm), and Feed rate (18mm/min). In addition, a mathematical model is created to predict the material removal

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