Manufacturing Technology Today

Rupinder Singh ¹, Jaimal Singh Khamba ²

Affiliations
1 Mechanical & Production Engineering Department, G.N.D.E.C, Ludhiana, IN
2 Mechanical Engineering Department, University College of Engineering, Punjabi University, Patiala, IN

Abstract

Ultrasonic Machining Process (USM) is a non-traditional machining technique, which is capable of providing excellent material removal rate along with surface finish on hard and brittle materials. Not much research work has hitherto been reported regarding machining characteristics of tough materials. The aim of this paper is to study the machining characteristics of tough materials with USM. The results of an experimental study conducted on titanium alloys using three different tool materials are reported. Surface roughness graphs have been obtained to gain insight in to the underlying wear pattern on the surface of titanium. The results suggest that toughness significantly affect the material removal rate in USM. Further, the composition of work material plays an important role in controlling the surface finish of the part.

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Rupinder Singh ¹, Jaimal Singh Khamba ²

Affiliations
1 Deptt. of Mechanical & Production Engineering, G.N.D.E. College, Ludhiana (Punjab), IN
2 Deptt. of Mechanical Engineering, T.I.E.T., Patiala (Punjab), IN

Abstract

In Ultrasonic machining of titanium alloys, remarkable effect of slurry type, grit size and concentration have been observed. This paper reports the result of an experimental study conducted using conventional tool material Stainless Steel and High Speed Steel with Alumina slurry, on Titanium alloys. The objective is to compare the Material Removal Rate and Tool Wear Rate of two different Titanium alloys i.e. TITAN 15 (ASTM Gr2) and TITAN 31 (ASTM Gr5). Machining properties of these alloys are compared using Ultrasonic Drilling Machine with different power rating at fix slurry concentration of alumina so that results can be used in manufacturing industry.

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Rupinder Singh ¹, Jaimal Singh Khamba ²

Affiliations
1 Department of Mechanical & Production Engineering, Guru Nanak Dev Engineering College, Ludhiana-141006, Punjab, IN
2 Mechanical Engineering Department, Thapar Institute of Engineering & Technology, Patiala, Punjab, IN

Abstract

Ultrasonic Machining is a non-conventional Machining process in which high frequency Ultrasonic Vibrations are used to machine brittle materials, which are otherwise difficult to machine. This process involves erosion as material removal mechanism, so obviously works better on hard materials. A lot of experimental work has been done on tool preparation for ultrasonic machining process. Commercially tool for Ultrasonic machining process are produced using silver brazing process. This paper aims at study of tool manufacturing technique for Ultrasonic drilling machine (For reference purpose Titanium {15} sample are chosen with 1801 No. (L&T) Silver Brazing rod was used). The size of rod was 1.6 mm diameter and 25mm* 0.075 mm shim; Tensile strength 63 Kg/mm2 (90,000 Psi), bonding temperature 600°C.The other set up includes 500 watt Ultrasonic drilling machine, with boron carbide slurry of 320 grit size using 40% concentration at 25.7°C slurry temperature.

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Rupinder Singh ¹, Jaimal Singh Khamba ²

Affiliations
1 Dept. of Mechanical & Production Engineering, G.N.D.E.C, Ludhiana, IN
2 Dept. of Mechanical Engineering, T.I.E.T, Patiala, IN

Abstract

In Ultrasonic Machining process, a recirculating pump forces slurry of abrasive materials suspended in liquid medium, such as water between tool face and work piece. The abrasive particles propelled by the tool strike the work piece at 150000 times their own weight. These tiny abrasive particles chip off microscopic flakes and grind a counterpart of the tool face. This paper mainly aims at study the effect of silicon carbide slurry on machining properties of Titanium alloy (TITAN15) ASTM Gr2 using 500 Watt Sonic-Mill Ultrasonic Drilling Machine with different power ratings at fix slurry concentration and temperature to establish relation between Material removal rate and Tool wear rate so that result can be helpful for manufacturing industry.

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