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.

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.

Monte Carlo Simulation of Seebeck Coefficient and Electrical Conductivity in Thermoelectrics

2013 ◽  
Vol 709 ◽  
pp. 176-179 ◽  
Author(s):  
Jian Li
Keyword(s):  
Electrical Conductivity ◽  
Monte Carlo Simulation ◽  
Grain Size ◽  
Monte Carlo ◽  
Seebeck Coefficient ◽  
Ground State ◽  
Proposed Model ◽  
Average Grain Size ◽  
Polycrystalline Ceramics ◽  
Simulation Results

we proposed a scheme for simulating the electronic and thermoelectric properties of polycrystalline ceramics. The simulation results show that the ground state electrons are easily confined in the largest grain. In addition, with the increasing average grain size, the Seebeck coefficient decreases while the electrical conductivity increases monotonically. The simulation results agree well with the available experimental results. Therefore, the proposed model is proved to be a promising approach for thermoelectric investigations.

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.

Effect of the Intercalation of the Carbon Layer on the Kinetics of Grain Growth of FePt Magnetic Thin Film during Ordering Reaction - A Monte Carlo Simulation Study

2007 ◽  
Vol 558-559 ◽  
pp. 1237-1242
Author(s):  
M.C. Kim ◽  
D.A. Kim ◽  
Joong Kuen Park
Keyword(s):  
Thin Film ◽  
Monte Carlo Simulation ◽  
Grain Size ◽  
Monte Carlo ◽  
Grain Growth ◽  
Carbon Layer ◽  
Carbon Addition ◽  
Monte Carlo Simulation Study ◽  
Ordering Kinetics ◽  
Kinetics Of

The effect of carbon addition on the grain growth and ordering kinetics of FePt film has been experimentally studied by sputter-depositing a monolithic FePt-20at.%C film of 24 nm. Carbon addition of 20at.% to FePt thin film in a form of FePt (20 nm)/Cn (4 nm) (n = 1, 4) significantly reduced both the grain growth and ordering kinetics. Reducing the thickness of carbon layer, i.e. from n = 1 to n = 4, led to a much finer grain size distribution as well as to a finer grain size. The Monte Carlo simulation study indicated that the decrease of grain growth and ordering kinetics is primarily due to a continuous decrease of the mobility of order – disorder inter-phase with the progress of ordering reaction. This can eventually lead to a stable 2-phase grain structure inter-locked by low mobility inter-phases and is responsible for the formation of a fine grain size distribution in the FePt/Cn film with n = 4.

scholarly journals Study on the relation among grain edge length, grain size and topology with Monte Carlo simulation

2009 ◽  
Vol 58 (13) ◽  
pp. 132
Author(s):  
Wang Hao ◽  
Liu Guo-Quan ◽  
Luan Jun-Hua ◽  
Yue Jing-Chao ◽  
Qin Xiang-Ge
Keyword(s):  
Monte Carlo Simulation ◽  
Grain Size ◽  
Monte Carlo ◽  
Edge Length ◽  
And Topology

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.

Micro Ultrasonic Machining Using Oil Based Abrasive Slurry

2008 ◽  
Author(s):  
Murali M. Sundaram ◽  
Sreenidhi Cherku ◽  
K. P. Rajurkar
Keyword(s):  
Particle Size ◽  
Material Removal Rate ◽  
Surface Finish ◽  
Material Removal ◽  
Removal Rate ◽  
Abrasive Particle ◽  
High Wear Resistance ◽  
Ultrasonic Machining ◽  
Influence Of Process Parameters ◽  
Slurry Concentration

Advanced engineering materials posses excellent properties such as high wear resistance, and inertness to corrosion and chemical reactions. Since these materials are usually hard, brittle, chemically inert, and electrically nonconductive, they pose serious machinability challenges. Micro ultrasonic machining (Micro USM) is an emerging method for the micromachining of hard and brittle materials without any thermal damage. This paper presents the results of micro ultrasonic machining using oil based abrasive slurry. Details of the in-house built experimental setup used to conduct the experiments are explained. The influence of process parameters such as slurry medium, slurry concentration, and abrasive particle size on the performance of micro USM are reported. It was noticed that the evidence of three body material removal mechanism is predominant for micro USM using oil based slurry. In general, the material removal rate increases with the increase in the abrasive particle size for both aqueous abrasive slurry and oil based abrasive slurry. Further, material removal rate is consistently higher for experiments conducted with aqueous abrasive slurry medium. On the other hand, it is noticed that the oil based slurry medium provides better surface finish. It is also noticed that the smaller abrasive grains provide better surface finish for both aqueous, and oil based abrasive slurry mediums. Role of slurry concentration is ambiguous, as no clear trend of its effect of on process performance is evident in the available experimental results.

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