Rotary ultrasonic machining of alumina ceramic: Experimental study and optimization of machining responses
Abstract
In the present competitive structure of manufacturing and industrial applications, alumina ceramic has been well observed as one of the highly demanded advanced ceramics owing to its excellent and superior properties. The objective of this article is to experimentally investigate the influence of several process variables namely; spindle speed, feed rate, coolant pressure, and ultrasonic power on different machining performances i.e. surface roughness, and chipping thickness. Response surface methodology has been employed to design the experiments. Microstructure of the machined samples has been evaluated and analyzed through scanning electron microscope. The existence of plastic deformation has also been observed along with the dominated brittle fracture in rotary ultrasonic machining of alumina ceramic. Feed rate and spindle speed have been observed as most influential parameters that govern the deformation mode in alumina ceramic. The optimization of machining responses has also been conducted by employing desirability theory, and at optimized parametric setting, the obtained experimental values for surface roughness and chipping thickness are, 0.134 µm and 0.073 mm, respectively.
References
Bertsche, E., Ehmann, K. & Malukhin, K. 2013. Ultrasonic slot machining of a silicon carbide matrix composite. International Journal of Advanced Manufacturing Technology 66(5-8): 1119-1134.
Churi, N.J., Pei, Z.J., Shorter, D.C. & Treadwell, C. 2009. Rotary ultrasonic machining of dental ceramics. International Journal of Machining and Machinability of Materials 6(3-4): 270-284.
Cong, W.L., Pei, Z.J. & Treadwell, C. 2014. Preliminary study on rotary ultrasonic machining of CFRP/Ti stacks. Ultrasonics 54(6): 1594-1602.
Cong, W.L., Pei, Z.J., Feng, Q., Deines, T.W. & Treadwell, C. 2012. Rotary ultrasonic machining of CFRP: a comparison with twist drilling. Journal of Reinforced Plastics and Composites 31(5): 313-321.
Dubey, A.K. & Yadava, V. 2008. Laser beam machining- a review. International Journal of Machine Tools and Manufacture 48: 609-628.
Falamaki, C. & Beyhaghi, M. 2009. Slip casting process for the manufacture of tubular alumina microfiltration membranes. Materials Science-Poland 27(2): 427-441.
Geng, D., Zhang, D., Xu, Y., He, F. & Liu, F. 2014. Comparison of drill wear mechanism between rotary ultrasonic elliptical machining and conventional drilling of CFRP. Journal of Reinforced Plastics and Composites 33(9): 797-809.
Gong, H., Fang, F.Z. & Hu, X.T. 2010. Kinematic view of tool life in rotary ultrasonic side milling of hard and brittle materials. International Journal of Machine Tools and Manufacture 50: 303-307.
Hu, P., Zhang, J.M., Pei, Z.J. & Treadwell, C. 2002. Modeling of material removal rate in rotary ultrasonic machining: designed experiments. Journal of Materials Processing Technology 129(1): 339-344.
Jiao, Y., Liu, W.J., Pei, Z.J., Xin, X.J. & Treadwell, C. 2005. Study on edge chipping in rotary ultrasonic machining of ceramics: an integration of designed experiments and finite element method analysis. Journal of Manufacturing Science and Engineering 127(4): 752-758.
Kataria, R., Kumar, J. & Pabla, B.S. 2015. Experimental investigation into the hole quality in ultrasonic machining of WC-Co composite. Materials and Manufacturing Processes 30(7): 921-933.
Kataria, R., Kumar, J. & Pabla, B.S. 2016. Experimental investigation and optimization of machining characteristics in ultrasonic machining of WC-Co composite using GRA method. Materials and Manufacturing Processes 31(5): 685-693.
Li, Z.C., Cai, L.W., Pei, Z.J. & Treadwell, C. 2006. Edge-chipping reduction in rotary ultrasonic machining of ceramics: finite element analysis and experimental verification. International Journal of Machine Tools and Manufacture 46(12): 1469-1477.
Li, Z.C., Jiao, Y., Deines, T.W., Pei, Z.J. & Treadwell, C. 2005. Rotary ultrasonic machining of ceramic matrix composites: feasibility study and designed experiments. International Journal of Machine Tools and Manufacture 45(12): 1402-1411.
Liu, J.W., Baek, D.K. & Ko, T.J. 2014. Chipping minimization in drilling ceramic materials with rotary ultrasonic machining. International Journal of Advanced Manufacturing Technology 72(9-12): 1527-1535.
Patel, K.M., Pandey, P.M. & Rao, P.V. 2011. Study on machinability of Al2O3 ceramic composite in EDM using response surface methodology. Journal of Engineering Materials and Technology 133: 021004-1-10.
Pei, Z.J., Ferreira, P.M. & Haselkorn, M. 1995. Plastic flow in rotary ultrasonic machining of ceramics. Journal of Materials Processing Technology 48(1): 771-777.
Singh, B., Kumar, J. & Kumar, S. 2014. Experimental investigation on surface characteristics in powder-mixed electrodischarge machining of AA6061/10% SiC composite. Materials and Manufacturing Processes 29(3): 287-297.
Singh, R.P. & Singhal, S. 2016. Rotary ultrasonic machining: a review. Materials and Manufacturing Processes doi: 10.1080/10426914.2016.1140188.
Singh, R.P., Kumar, J., Kataria, R. & Singhal, S. 2015. Investigation of the machinability of commercially pure titanium in ultrasonic machining using graph theory and matrix method. Journal of Engineering Research 3(4): 75-94.
Ya, G., Qin, H.W., Xu, Y.W. & Zhang, Y.S. 2001. An experimental investigation on rotary ultrasonic machining. Key engineering materials 202: 277-280.
Zeng, W.M., Xu, X.P. & Pei, Z.J. 2009. Experimental investigation of tool wear in rotary ultrasonic machining of alumina. Key Engineering Materials 416: 182-186.
Zhang, C., Cong, W., Feng, P. & Pei, Z. 2014. Rotary ultrasonic machining of optical K9 glass using compressed air as coolant: A feasibility study. Part B: Journal of Engineering Manufacture 228(4): 504-514.
Zhang, C.L., Feng, P.F., Wu, Z.J. & Yu, D.W. 2011. An experimental study on processing performance of rotary ultrasonic drilling of K9 glass. Advanced Materials Research 230: 221-225.
