Manufacturing Technology Today

Jatinder Kumar ¹, J. S. Khamba ², S. K. Mohapatra ³

Affiliations
1 Dept. of Mechanical Engg., AKGEC, Ghaziabad, IN
2 Dept. of Mechanical Engg, UCOE, Punjabi University, Patiala, IN
3 Dept. of Mechanical Engg., TIET, Patiala, IN

Abstract

Ultrasonic Machining is one of the most widely used non-traditional machining processes for the machining of non-conductive, brittle materials such as engineering ceramics. Although USM can machine any material regardless of its electrical conductivity, the machining performance of this process is dependent on several important mechanical properties of the work material being machined, including fracture toughness and hardness. There is a considerable lack of research on this aspect of USM, particularly the performance of the process with different work-tool combinations and under varying process conditions such as slurry grit size, tool material, abrasive material etc. In the present investigation, an experimental study has been conducted to assess the effect of slurry grit size on Machining rate and tool wear rate with twelve different work-tool combinations. It has been concluded that the abrasive grit size plays an important role in the variation of the machining performance of USM. The machining rate is found to decrease with a corresponding increase in the product of fracture toughness and hardness of the work material. Tool wear rate decreases with decrease in the fracture toughness of work material and increase in the strain hardening capability of tool material.

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Jatinder Kumar ¹, J. S. Khamba ², S. K. Mohapatra ³

Affiliations
1 Dept. of Mechanical Engg., AKGEC, Ghaziabad, IN
2 Dept. of Mechanical Engg., UCOE, Punjabi University, Patiala, IN
3 Dept. of Mechanical Engg., TIET, Patiala, IN

Abstract

This paper reviews the fundamental principles of ultrasonic machining; the modes and mechanisms of material removal and the effect of operating parameters on the performance indices-material removal rate (MRR), tool wear rate (TWR) and surface roughness. The issues of production accuracy and precision in drilling deep holes have also been explored. A brief review on process application to the machining of titanium-considered as a tough material has also been presented. It has been concluded from the experimental study that ultrasonic machining could be applied effectively for machining titanium. When applied to titanium, ultrasonic machining results in low material removal rate (MRR), high tool wear rate (TWR) and low surface roughness.

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