Improving hole exit quality in rotary ultrasonic machining of ceramic matrix composites using a compound step-taper drill

Wang, Jianjian; Feng, Pingfa; Zheng, Jingzhen

doi:10.1016/j.ceramint.2016.05.095

Cited by 61 publications

(11 citation statements)

References 20 publications

(25 reference statements)

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“…Figure 8a and Figure 8b show the three mechanisms that form the exit delamination (i.e. tearing, burring and edge chipping) and the influence that this damages have depending on the fibre orientation [32], [33]. Several authors [34]- [37] concluded that Rotary Ultrasonic Machining (RUM) produced an overall lower thrust force (≈10-15% [34]) which was translated to a less significant exit delamination.…”

Section: Figure 7 Influence Of the Fibre Orientation When Drilling Perpendicular And Tilted Holes In Orthotropic Materials Such As Cmcsmentioning

confidence: 99%

The new challenges of machining Ceramic Matrix Composites (CMCs): Review of surface integrity

Gavaldà-Diaz

Luna

Liao

et al. 2019

International Journal of Machine Tools and Manufacture

224

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Ceramic Matrix Composites (CMCs) are currently an increasing material choice for several high value and safety-critical components, fact that has recently originated the need of understanding the effect of several machining processes. Due to the complex nature of CMCs -i.e. heterogeneous structure, anisotropic thermal and mechanical behaviour and generally the hard nature of at least one of the constituents (e.g. fibre or matrix)machining become extremely challenging as the process can yield high mechanical and thermal loads. Furthermore, the orthotropic, brittle and heterogeneous nature of CMCs result in different material removal mechanisms which lead to unique surface defects. Hence, this review paper attempts to provide an informative literature survey of the research done in the field of conventional and non-conventional machining of CMCs with a main focus on critically evaluate how different machining techniques affect the machined surfaces. This is achieved by exploring and recollecting the different material characterisation techniques currently used to observe and quantify the mechanical and thermal surface and subsurface damages and highlight their governing removal mechanisms.

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Section: Figure 7 Influence Of the Fibre Orientation When Drilling Perpendicular And Tilted Holes In Orthotropic Materials Such As Cmcsmentioning

confidence: 99%

The new challenges of machining Ceramic Matrix Composites (CMCs): Review of surface integrity

Gavaldà-Diaz

Luna

Liao

et al. 2019

International Journal of Machine Tools and Manufacture

224

View full text Add to dashboard Cite

show abstract

“…There are issues with ultrasonic machining also, such as due to stress concentration at the periphery of the hole exit a fracture at the edges occurs [19]. Wang et al [20] employed a unique blended step-taper diamond core drill for RUM of C/ SiC to enhance the hole exit accuracy. The results indicated that the compound drill could be useful to minimize the tearing size by thirty percent.…”

Section: Introductionmentioning

confidence: 99%

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

Alkhalefah

2020

Materials

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Alumina is an advanced ceramic with applications in dental and medical sciences. Since ceramics are hard and brittle, their conventional machining is expensive, arduous, and time-consuming. As rotary ultrasonic machining is among the most adequate and proficient processing techniques for brittle materials like ceramics. Therefore, in this study, rotary ultrasonic drilling (RUD) has been utilized to drill holes on alumina ceramic (Al2O3). This study investigates the effect of key RUD process variables, namely vibration frequency, vibration amplitude, spindle speed, and feed rate on the dimensional accuracy of the drilled holes. A four-variable three-level central composite design (thirty experiments on three sample plates) is utilized to examine the comparative significance of different RUD process variables. The multi-objective genetic algorithm is employed to determine the optimal parametric conditions. The findings revealed that material removal rates depend on feed rate, while the cylindricity of the holes is mostly controlled by the speed and feed rate of the spindles. The optimal parametric combination attained for drilling quality holes is speed = 4000 rpm, feed rate = 1.5 (mm/min), amplitude = 20 (µm), and frequency = 23 (kHz). The validation tests were also conducted to confirm the quality of drilled holes at the optimized process parameters.

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“…Kumaran et al [12] inferred reduced burr at hole exit at the expense of increased thrust force in RUD of CFRP composite under low temperature conditions. Wang et al [28] addressed the reduction in tearing size and drilling forces due to reprocessing effect of compound step drill during RUD of C/SiC. During RUD of quartz glass and sapphire, Wang et al [29] reported 60% reduction in edge chipping with step drills having step thickness smaller than the thickness of drill end face.…”

Section: Introductionmentioning

confidence: 99%

Investigation of hole quality in rotary ultrasonic drilling of borosilicate glass using RSM

Kumar

Singh

2018

J Braz. Soc. Mech. Sci. Eng.

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The present article emphasizes on reducing the edge chipping and taper during rotary ultrasonic drilling of one of the most demanded ceramic glasses "BK-7." Statistical tools of design of experiments and backing plate were adopted as two distinct approaches to curb the chipping damage. Central composite design has been conjugated with desirability function for framing the design matrix. This investigation also emphasizes to study the effect of process variables-spindle speed, ultrasonic power and feed rate-on the chipping width (CW) and taper (T). After developing the second-order regression models for the CW and T, analysis of variance was used to check the fitness of regression models and recognizing the significant model terms. Then impact of each process parameter was analyzed on responses of interest through 3-D surface plots. The feed rate came forth as the most dominating factor by having maximum influence over the qualitative aspects "CW" and "T" of the drilling process. Interactions of higher rpm and power with lower feed effectively reduced the CW and T. The backing material, employed during main experimentation, also proved its effectiveness to reduce CW when main experiments results were compared to the results of pilot experimentation, which was performed without backing plate. Scanning electron microscope (SEM) was used to analyze the different tool wear modes and microstructure of machined surfaces. Tool weight measurement revealed the dominance of bond fracture and grain fracture during the early stage of the drilling process. Apart from brittle fracture, SEM also affirmed the presence of plastically deformed regions over the machined surfaces. Little deviations between the predicted values and experimental values during the confirmatory tests validated the prediction accuracy of regression models at 95% confidence level.

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Improving hole exit quality in rotary ultrasonic machining of ceramic matrix composites using a compound step-taper drill

Cited by 61 publications

References 20 publications

The new challenges of machining Ceramic Matrix Composites (CMCs): Review of surface integrity

The new challenges of machining Ceramic Matrix Composites (CMCs): Review of surface integrity

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

Investigation of hole quality in rotary ultrasonic drilling of borosilicate glass using RSM

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