Experimental Investigation of Performance Characteristics of an Ultrasonic Machining Process

Abstract

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. 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 three different grit sizes has been taken. The concentration of abrasive slurry has been taken differently. Grit size used were 320, 400, 600 mesh. In this experiment three work piece were used i.e. Metal matrix composites with Aluminium as baseline material with ZrO2, SiC and Al3Zr as particulate reinforcement in respective three work pieces. Power output, slurry concentration, slurry type and grit size were variable input parameters Finally, the effect of ultrasonic machining process 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 of machined surface were measured 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.