Rotary ultrasonic machining of alumina ceramic: Experimental study and optimization of machining responses

  • Ravi Pratap Singh Department of Mechanical Engineering National Institute of Technology Kurukshetra-136119 Haryana India
  • Sandeep Singhal Department of Mechanical Engineering National Institute of Technology Kurukshetra-136119 Haryana India
Keywords: Rotary ultrasonic machining, alumina ceramic, surface roughness, chipping thickness, response surface methodology

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.

Author Biographies

Ravi Pratap Singh, Department of Mechanical Engineering National Institute of Technology Kurukshetra-136119 Haryana India

Ph.D. Research Scholar

Department of Mechanical Engineering
National Institute of Technology
Kurukshetra-136119
Haryana
India

Sandeep Singhal, Department of Mechanical Engineering National Institute of Technology Kurukshetra-136119 Haryana India

Associate Professor

Department of Mechanical Engineering

National Institute of Technology

Kurukshetra-136119

Haryana

India

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Published
2018-05-02
Section
Mechanical Engineering