Modeling, Analysis, Coding, Evaluation and Selection of Ultrasonic Machining System

Abstract

Ultrasonic machining is one of the most widely used non-traditional machining processes for the machining of non-conductive, brittle materials including glass, ceramics, carbides, and graphite. Ultrasonic machining is an abrasive process, and material removal is purely mechanical. The process does not cause heat affected zone and any chemical or electrical alterations on work piece surface. It does not change the metallurgical, chemical or physical properties of the work pieces. Ultrasonic machine four different mechanisms are responsible for removal of material from the work surface. Material removed by direct hammering of abrasive particles on the work piece, Micro chipping by impact of free moving particles, Cavitations effect from the abrasive slurry, Chemical action associated with the fluid used. This study presents a new methodology for evaluation, ranking and selection of parameters of Ultrasonic machine by using (multiple attribute decision making) MADM approach. A 3- stage selection procedure is used for identification of pertinent attributes and ranking is done with TOPSIS and graphical methods (Line graph and Spider Diagram). The proposed 3-stage selection procedure is explained with the help of an illustrative example. This methodology convert database into knowledge base by considering normalization, relative weights, positive benchmarked and negative benchmarked solutions. This study provides a general formula which can be applied to any USM system. An integrated systems model for the structure of the ultrasonic machining system in terms of its constituents and interactions between the processes using graph theory and matrix algebra. Ultrasonic machining system is first explained with the graph theoretic approach using different interactions between sub systems. The matrix models and variable permanent function models provides an opportunity for carrying out characterization analysis and optimization. The terms of permanent multinomial characterize the ultrasonic machining system uniquely and for analysis of the structural information of the ultrasonic machining system.