Experimental investigation of machining characteristics in rotary ultrasonic machining of quartz ceramic

Abstract

Quartz ceramic has been well observed as one of the highly demanded advanced ceramics which is receiving enlarging industrial approbation owing to its excellent and superior properties. However, its fruitful processing with traditional and non-traditional machining methods is still a challenge. The current article has aimed to experimentally investigate the influence of several process variables, namely, spindle speed, feed rate, coolant pressure, and ultrasonic power on machining characteristics of interest, i.e. chipping size, and material removal rate in rotary ultrasonic machining of quartz ceramic. Response surface methodology has been employed to design the experiments and the variance analysis test has also been performed with a view to observe the significance of considered parameters. Microstructure of machined samples has also been evaluated and analyzed using scanning electron microscope. This analysis has revealed and confirmed the presence of dominating brittle fracture that caused removal of material along with the slighter plastic deformation in rotary ultrasonic machining of quartz ceramic. The soundness and competence of the developed mathematical model have been established with test results. The multi-response optimization of machining responses has also been done by utilizing desirability approach, and at optimized parametric setting, the obtained experimental values for material removal rate and chipping size are, 0.6437 mm 3 /s and 1.3326 mm, respectively, with the combined desirability index value of 0.949.

Decision-Making in Real-Life Industrial Environment through Graph Theory Approach

“…This methodology is particularly based on the advanced theory of graphs, and therefore its applications are very well renowned. The demonstration through graph "or" digraph model has proven to be useful for modeling and analyzing numerous varieties of systems and problems in numerous fields of science and technology [7][8][9]. The approach based on the matrix method is useful in analyzing the graph/digraph models expeditiously to derive the system function and index to meet the objectives.…”

Investigation of machining rate and roughness for rotary ultrasonic drilling of Inconel 718 alloy with slotted diamond metal bonded tool

“…A conventional diamond cutting method aided with ultrasonic vibration has come into existence in the form of hybrid machining method called rotary ultrasonic machining (RUM) in which a high frequency oscillating and rotary metal bonded diamond core drill tool enables it to machine hard and complex materials (i.e., ceramic, super alloys, titanium, etc.). In addition, no heat treated/affected zone is created after machining with RUM process (Singh and Singhal, 2016a;Abdo et al, 2013;Feng and Xu, 2012). The effective trial of RUM process as an ultrasonic milling was carried out by Pei et al in 1995. The application of this hybrid method was extended to the drilling, grinding and face milling of ceramics with preliminary experiments.…”

“…The highest MRR was obtained at a combination of high power rating and coarse grit size. Singh and Singhal (2016a, 2016b, 2016c investigated the machining characteristics of Al 2 O 3 and quartz ceramic by employing an experimental design approach through response surface methodology (RSM) and concluded that higher feed rate gives the best solution with respect to MRR. Increased spindle speed leads to an increase in the volume of indentation proportionally, which further caused higher MRR.…”

“…The deep indentations mark present over the surface, further promote the removal of material from machining surface. Higher tool rotation is showing great influence over the machined work surface (Singh and Singhal, 2016a;Pi et al, 2013). This removal of material in the form of bigger chunks is due to the higher feed rates that cause the larger indentation of abrasives into the work surface.…”

Electro-Discharge Machining of Ceramics: A Review

“…Considering its contributions to environmental hazards, chemical machining [13,14] is not considered as an environmentally friendly process. Other non-contact processes such as laser machining [15,16,17,18], plasma machining [19,20], electron beam machining [21,22,23], electrochemical machining [24,25,26,27], ultrasonic machining [28,29,30,31,32], and abrasive water jet machining [33,34,35,36,37] also have their advantages and disadvantages as reported by different researchers. Therefore, non-contact machining processes have received more attention considering they employ no-force machining as well as recognize the brittleness of the ceramic materials.…”