Improving Ultrasonic Machining Rates—Some Feasibility Studies

1965 ◽  
Vol 87 (1) ◽  
pp. 39-46 ◽  
Author(s):  
W. Pentland ◽  
J. A. Ektermanis
Keyword(s):  
Heat Treatment ◽  
Plastic Deformation ◽  
Vibration Amplitude ◽  
Removal Rate ◽  
Feasibility Studies ◽  
Machining Process ◽  
Particle Removal ◽  
Ultrasonic Machining ◽  
Temperature Liquid ◽  
Material Tool

Investigations are reported on the influence on removal rate of slurry liquid cavitation, low temperature, liquid metal, and stress corrosion embrittlement of the work material, tool vibration amplitude, grit size and method of application of slurry, and the influence of heat-treatment and applied stress conditions of the workpiece. From these studies it is postulated that there may be three basic mechanisms involved in the ultrasonic machining process—microchip removal and material displacement by plastic deformation, and particle removal by fracture.

scholarly journals Electromechanical Dynamics Model of Ultrasonic Transducer in Ultrasonic Machining Based on Equivalent Circuit Approach

Sensors ◽  
2019 ◽  
Vol 19 (6) ◽  
pp. 1405
Author(s):  
Jian-Guo Zhang ◽  
Zhi-Li Long ◽  
Wen-Ju Ma ◽  
Guang-Hao Hu ◽  
Yang-Min Li
Keyword(s):  
Removal Rate ◽  
Ultrasonic Transducer ◽  
Mechanical Vibration ◽  
Electrical Energy ◽  
Structure Design ◽  
Machining Process ◽  
Ultrasonic Machining ◽  
Impedance Model ◽  
Impedance Characteristics ◽  
Electromechanical Dynamics

Ultrasonic transducer is a piezoelectric actuator that converts AC electrical energy into ultrasonic mechanical vibration to accelerate the material removal rate of workpiece in rotary ultrasonic machining (RUM). In this study, an impedance model of the ultrasonic transducer is established by the electromechanical equivalent approach. The impedance model not only facilitates the structure design of the ultrasonic transducer, but also predicts the effects of different mechanical structural dimensions on the impedance characteristics of the ultrasonic transducer. Moreover, the effects of extension length of the machining tool and the tightening torque of the clamping nut on the impedance characteristics of the ultrasonic transducer are investigated. Finally, through experimental analysis, the impedance transfer function with external force is established to analyze the dynamic characteristics of machining process.

Dynamic Analysis of the Ultrasonic Machining Process

1996 ◽  
Vol 118 (3) ◽  
pp. 376-381 ◽  
Author(s):  
Z. Y. Wang ◽  
K. P. Rajurkar
Keyword(s):  
Dynamic Analysis ◽  
Material Removal ◽  
Removal Rate ◽  
Equations Of Motion ◽  
Three Dimensional ◽  
Dynamic Contact ◽  
Machining Process ◽  
Ultrasonic Machining ◽  
Factors Affecting ◽  
Good Agreement

This paper presents a dynamic analysis of the ultrasonic machining process based on impact mechanics. Equations representing the dynamic contact force and stresses caused by the impinging of abrasive grits on the work, are obtained by solving the three-dimensional equations of motion. The factors affecting the material removal rate have been studied. It is found that the theoretical estimates obtained from the dynamic model are in good agreement with the experimental results.

scholarly journals Process parameter optimization of Al/SiC metal matrix composites during ultrasonic machining process

2021 ◽  
Vol 309 ◽  
pp. 01156
Author(s):  
Bikash Banerjee ◽  
Arindam Chakraborty ◽  
Somnath Das ◽  
Debabrata Dhupal
Keyword(s):  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Removal Rate ◽  
Optimization Technique ◽  
Research Work ◽  
Machining Process ◽  
Matrix Composites ◽  
Ultrasonic Machining ◽  
Response Parameter ◽  
Through Hole

Metal matrix is highly acceptable composites providing good strength for industrial use. In many field of industries, especially aerospace industry metal matrix composites of type Al/SiC is used because of its superior properties. In this research work, experimentalanalysis has been done for producing through hole on metal matrix composites with suitable quality ultrasonic machining (USM) process. Three unconstrained process parameters are chosen, like abrasive slurry concentration, power rating sand tool feed rate. Material removal rate (MRR) is considered as response parameter. The effects of each parameter have been analyzed here. Analysis of variance (ANOVA) has also been applied to identify the most significant factor. Response surface methodology (RSM) has been utilized to developed empirical model for determine the performance of ultrasonic process. Optimization technique has been used to find out the maximum process MRR. Confirmation verification test has been done to improve optimal parametric condition for getting maximum MRR. This research paper gives viability application of USM process for producing of through hole on metal matrix composites and various applications in industry.

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.

Analysis of Ultrasonic Machining Using Monte Carlo Simulation

2011 ◽  
Author(s):  
Chittaranjan Sahay ◽  
Suhash Ghosh ◽  
Hari Kiran Kammila
Keyword(s):  
Monte Carlo Simulation ◽  
Grain Size ◽  
Monte Carlo ◽  
Removal Rate ◽  
Abrasive Particle ◽  
Negative Relationship ◽  
Machining Process ◽  
Analysis Tool ◽  
Ultrasonic Machining ◽  
Strong Positive Relationship

Proper selection of manufacturing conditions is one of the most important aspects in Ultrasonic Machining process, as these conditions determine the Material Removal Rate (MRR). In this work, two very popular mathematical models proposed by Miller and Shaw have been investigated using Monte Carlo simulation based Crystal Ball analysis tool. Effects of abrasive particle size, particle concentration, amplitude of tool vibration, tool radius and depth of hole on MRR have been analyzed for both models. Miller’s model indicates a strong positive relationship between abrasive grain size, concentration and MRR. Contrary to the literature search on experimental data, Shaw’s mathematical model indicates a negative relationship between MRR and grain size, and a very weak relationship between MRR and concentration. No definite relationship could be established between either tool radius and MRR or amplitude and MRR. A negative relationship between depth of hole and MRR was obtained for Shaw’s model.

Study of Micro Ultrasonic Machining of Silicon

2005 ◽  
Author(s):  
Z. Yu ◽  
X. Hu ◽  
K. P. Rajurkar
Keyword(s):  
Material Removal ◽  
Removal Rate ◽  
Abrasive Particle ◽  
Machining Process ◽  
Machining Parameters ◽  
Ultrasonic Machining ◽  
Debris Accumulation ◽  
Micro Holes ◽  
Short Time ◽  
Mechanical Machining

As a micro mechanical machining process, micro ultrasonic machining (micro USM) has the major advantage of producing micro-scale components or features in brittle (glass, quartz crystal, and sapphire) and hard (ceramics) materials. Micro USM is used to generate micro holes with 5μm in diameter and 3D micro cavities. However, the relationship of machining parameters such as static load, abrasive particle and amplitude of vibration and the material removal rate is not clearly understood. In this paper, a mathematical model is developed to describe the material removal process in micro USM. Experiments were carried out to verify the model. It was found that the machining speed decreases when the load is over a certain value, which is different from that of theoretical model. To understand this phenomenon, a simple model was proposed to analyze it qualitatively. It was found that the debris accumulation around the crater in a short time is the main reason resulting in the low machining efficiency.

Rotary Ultrasonic Machining of Advanced Ceramics

2006 ◽  
Vol 532-533 ◽  
pp. 361-364 ◽  
Author(s):  
Wei Min Zeng ◽  
Xi Peng Xu ◽  
Zhi Jian Pei
Keyword(s):  
Material Removal ◽  
Removal Rate ◽  
Cost Effective ◽  
Machining Process ◽  
Future Research ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Advanced Ceramics ◽  
Material Removal Mechanisms ◽  
Removal Mechanisms

Rotary ultrasonic machining (RUM) is one of the cost-effective machining methods for advanced ceramics, which is a hybrid machining process that combines the material removal mechanisms of diamond grinding and ultrasonic machining (USM). This paper presents an overview of the investigations on RUM of advanced ceramics. The issues about the material removal mechanisms, process modeling, material removal rate, and tool wear in RUM are reviewed. Directions of future research on RUM are also presented.

Performance Analysis on Eco-friendly Machining of Ti6Al4V using Powder Mixed with Different Dielectrics in WEDM

2020 ◽  
Vol 17 (3) ◽  
pp. 8128-8139
Author(s):  
S. Chakraborty ◽  
S. Mitra ◽  
D. Bose
Keyword(s):  
Metal Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Process Efficiency ◽  
Machining Parameters ◽  
Dielectric Fluids ◽  
High Emission ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

The recent scenario of modern manufacturing is tremendously improved in the sense of precision machining and abstaining from environmental pollution and hazard issues. In the present work, Ti6Al4V is machined through wire EDM (WEDM) process with powder mixed dielectric and analyzed the influence of input parameters and inherent hazard issues. WEDM has different parameters such as peak current, pulse on time, pulse off time, gap voltage, wire speed, wire tension and so on, as well as dielectrics with powder mixed. These are playing an essential role in WEDM performances to improve the process efficiency by developing the surface texture, microhardness, and metal removal rate. Even though the parameter’s influencing, the study of environmental effect in the WEDM process is very essential during the machining process due to the high emission of toxic vapour by the high discharge energy. In the present study, three different dielectric fluids were used, including deionised water, kerosene, and surfactant added deionised water and analysed the data by taking one factor at a time (OFAT) approach. From this study, it is established that dielectric types and powder significantly improve performances with proper set of machining parameters and find out the risk factor associated with the PMWEDM process.

Optimization of μEDM process assisted with rotating magnetic pulling force and ultrasonic vibration

2021 ◽  
pp. 095440892098440
Author(s):  
Gurpreet Singh ◽  
DR Prajapati ◽  
PS Satsangi
Keyword(s):  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Micro Electrical Discharge Machining ◽  
Pulling Force ◽  
Tool Rotation

The micro-electrical discharge machining process is hindered by low material removal rate and low surface quality, which bound its capability. The assistance of ultrasonic vibration and magnetic pulling force in micro-electrical discharge machining helps to overcome this limitation and increase the stability of the machining process. In the present research, an attempt has been made on Taguchi based GRA optimization for µEDM assisted with ultrasonic vibration and magnetic pulling force while µEDM of SKD-5 die steel with the tubular copper electrode. The process parameters such as ultrasonic vibration, magnetic pulling force, tool rotation, energy and feed rate have been chosen as process variables. Material removal rate and taper of the feature have been selected as response measures. From the experimental study, it has been found that response output measures have been significantly improved by 18% as compared to non assisted µEDM. The best optimal combination of input parameters for improved performance measures were recorded as machining with ultrasonic vibration (U1), 0.25 kgf of magnetic pulling force (M1), 600 rpm of tool rotation (R2), 3.38 mJ of energy (E3) and 1.5 mm/min of Tool feed rate (F3). The confirmation trail was also carried out for the validation of the results attained by Grey Relational Analysis and confirmed that there is a substantial improvement with both assistance applied simultaneously.

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.

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