Analysis of the Material Removal Rate of Micro-Hole Machining of Ceramic Materials

Abstract

This study discussed what rotary ultrasonic machining (RUM) and tool geometry parameters combination can obtain bigger material removal rate (MRR) in drilling. The experimental configuration of this study was planned using Taguchi orthogonal array, where the drill diameter, rotation speed, power and feed rate were taken as the experimental factors. A relation model among the MRR and standard deviation of the holes walls and processing parameters and tool geometry was established, so as to achieve maximum MRR of the overall deep holes walls. The experimental results proved that application of the optimized parameters combination in rotary ultrasonic machining of holes processing can obtain bigger and better removal rate of holes walls. The effect of control factors on the holes quality was discussed from the straightness deviation and maximum material removal rate of related factors on the holes when the Taguchi method was used in rotary ultrasonic machining of holes drilling. The results showed that rotation speed, power, and feed rate under bigger level have a larger MRR than that of other level in a fixed drill diameter.

Precise Drilling of Holes in Alumina Ceramic (Al2O3) by Rotary Ultrasonic Drilling and its Parameter Optimization using MOGA-II

“…For example, Li et al [18] conducted investigations for ceramic matrix composites and identified an improvement in MRR with a feed rate increase. Similarly, the outcome of the study carried out by Jiao et al [38] and Wang and Chueh [39] is consistent with the findings of the current investigation. Kumar and Singh [36] have also suggested that the feed rate must be carefully chosen to achieve better machining efficiency.…”