Exprimental Investigation of Performance Characteristics of an Ultrasonic Machining Process

Abstract

This is an attempt to determine performance characteristics in order to facilitate the machining objectives of high accuracy, high efficiency and low cost in ultrasonic vibration cutting. Also this work deals with the optimization of performance characteristics of an ultrasonic machining process. Ultrasonic machining is one of the most widely used non-traditional machining processes for the machining of non-conductive, brittle materials. Unlike other processes, ultrasonic machining does not damage the work surface thermally which contributes to the successful performance of these materials in service. Ultrasonic vibration cutting as a cutting process has been widely used in the precision machining of difficult to cut materials due to an enhanced cutting stability and increased productivity. Ultrasonic machining is a technology driven process used for machining or finishing brittle abrasives or materials. Its material removal mechanism includes impacting, hammering and cavitations. The USM is effective and practical for all brittle materials, including glass, ceramics, carbides, and graphite. The experiments have been performed on ultrasonic machine, Sonic Mill, 500 Watts (USA).The abrasive slurries alumina and silicon carbide of two different grit sizes has been taken. Two types of alumina (alumina oxide neutral and alumina oxide base) have been taken. The concentration of abrasive slurry has been taken differently. The grit taken during the study is 400 and 220 mesh size. In these experiments, grit size, abrasive slurry concentration, , voltage have been taken as input parameters. Finally, the effect of ultrasonic vibration cutting on tool and work materials has been investigated experimentally by examining the surface roughness, micro-structure, surface hardness, material removal rate as output parameters. The machined surfaces have been analyzed by using the scanning electron microscope (SEM) and surface roughness values were measured at entry and at exit of the holes for different types and sizes of holes using the surface roughness measuring instrument “Perthometer M4pi”. In addition to discussing the characteristics, also an attempt has been made to optimize the process parameters proposed by various researchers, as well as to review and sample the wide variety of current applications of the same, in the field of Non-traditional machining.