A study on the effect of main process parameters of rotary ultrasonic machining for drilling BK7 glass

Abstract

BK7 glass is an important engineering material with extensive applications in high-quality and precision transmissive optical components. However, BK7 glass is considered to be a difficult-to-cut material due to its high brittleness and nonconductivity. This article presents the use of rotary ultrasonic machining process for drilling holes in BK7 glass. No previous reports have been found in the literature to experimentally investigate the response of the BK7 glass to rotary ultrasonic drilling. The experimental investigations take into account the effect of the key rotary ultrasonic machining input parameters including the ultrasonic power, spindle speed and feed rate on the output responses of cutting force, exit chipping, surface roughness, hole cylindricity and overcut errors, and surface integrity. The results show that the input parameters within the current ranges can significantly affect the quality of the drilled holes. Moreover, the selected level of any input parameter has the ability to significantly affect the influence of the other input parameters on the output responses. Through proper selection of input parameters, holes could be drilled in BK7 glass with less fractured topography, low surface roughness (1.32 mm), low exit chipping size (0.85), and very low cylindricity (3 mm) and overcut (73.6 mm) errors.

Experimental Analysis on the Influence and Optimization of μ-RUM Parameters in Machining Alumina Bioceramic

“…It can be seen in Figure 14 a,c that as the spindle speed increases and the feed rate decreases, the values of SEC and BEC reduce considerably. This happens because any change in input parameters which leads to an increase in the force between the tool and the workpiece means the edge chipping will increase [ 33 , 36 ]. Regarding the effect of ultrasonic parameters, no clear trend is observed, as shown in Figure 14 b,d.…”

Deep learning model for temperature prediction: A case study in New Delhi

“…The first layer of the DNN processes raw data (input) and passes it to the second layer called the hidden layer. The second layer processes the information further according to the activation function and passes it to the next layer Anwar et al (2017). This process is adopted by all the layers in the DNN until the desired result (output) is achieved.…”

Investigation into rotary mode ultrasonic drilling of bioceramic: an experimental study with PSO-TLBO based evolutionary optimization

“…), no temperature increase was observed using the RUM technique. Furthermore, cooling fluid has been supplied from the core of the drill and via the hoses, further protecting the machining zone from any temperature increase that may occur at extremely low feed rate levels (Anwar et al , 2018; Singh and Singhal, 2018a, 2018b; Singh et al , 2015).…”

“…), no temperature increase was observed using the RUM technique. Furthermore, cooling fluid has been supplied from the core of the drill and via the hoses, further protecting the machining zone from any temperature increase that may occur at extremely low feed rate levels (Anwar et al, 2018;Singhal, 2018a, 2018b;Singh et al, 2015). Wang et al (2018) used rotary ultrasonic machining to investigate the effects of tool orientations on response variables (cutting force and surface roughness) with varying process parameters on carbon fiber reinforced plastic composites (CFRP).…”

“…For marble and basalt, an abrasive concentration of 100 resulted in the least amount of cutting force. Anwar et al (2018) used rotary ultrasonic machining to drill BK7 optical glass using process parameters including ultrasonic power, spindle speed and feed rate and the results were surface roughness, cutting force, hole cylindricity, exit chipping size, surface integrity and overcut. With a higher feed rate and lower spindle speed surface roughness were increased.…”