Effect of process parameters on MRR, TWR and surface topography in ultrasonic machining of alumina–zirconia ceramic composite

Bhosale, Shrikrushna B.; Pawade, Raju S.; Brahmankar, P.K.

doi:10.1016/j.ceramint.2014.04.137

Cited by 41 publications

(13 citation statements)

References 14 publications

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“…The associate editor coordinating the review of this manuscript and approving it for publication was Yingxiang Liu. water jet machining, laser beam machining, and rotary ultrasonic machining (RUM) are invented to improve the machining efficiency [2]. Currently, RUM has become one of the dominant technologies for machining hard-brittle materials, because it not only reduces cutting force, improves surface quality and reduces tool wear, but also increases machining efficiency [3]- [6].…”

Section: Many Untraditional Machining Methods Including Abrasivementioning

confidence: 99%

Novel Optimization Approach in Ultrasonic Machining: Unilateral Compensation for Resonant Vibration in Primary Side

et al. 2019

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Resonant frequency and impedance matching have great significance for the vibration performance and online monitoring of the rotary ultrasonic machining. Network compensation is a typical solution to match the resonant frequency and the impedance between the rotary ultrasonic holder (RUH) and the ultrasonic transducer. However, the traditional bilateral compensation method could adversely affect the rotary dynamic balance of the RUH. Currently, the existing unilateral compensation methods can only realize the resonant frequency matching. A novel unilateral compensation method that satisfies both the resonant frequency and the impedance matching is proposed. First, the impedance model of the RUH vibrating system is established according to its equivalent circuit. It is found that, without any compensation methods, the resonant frequency and the impedance between the RUH and the transducer have deviated. Second, the primary-series and primary-parallel compensation topologies are applied to the RUH system, and the expressions of compensation capacitance value, voltage gain, power transfer efficiency, and output active power are derived. The deviations of the resonant frequency and the impedance are eliminated with primaryseries compensation topology; and as a result, the voltage gain is increased from 0.267 to 0.90, the output active power is 11.3 times than that without compensation. Third, the state-space model of primary-series topology is constructed. Finally, the above theoretical results are verified by the experimental results.

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Section: Many Untraditional Machining Methods Including Abrasivementioning

confidence: 99%

Novel Optimization Approach in Ultrasonic Machining: Unilateral Compensation for Resonant Vibration in Primary Side

et al. 2019

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show abstract

“…It was seen that, nature of whole integrity during USM can only be minimised using smaller grit size but cannot be eliminated. Bhosale et al (2014) studied the effect of USM responses such as material removal rate (MRR), tool wear rate (TWR) and surface topography on machining of alumina-zirconia (Al 2 O 3 -ZrO 2 ) ceramic composite. They used full factorial design for experimentation.…”

Section: Introductionmentioning

confidence: 99%

Experimental investigation and optimisation of ultrasonic machining parameters on zirconia composite

Biswas

Jagadish

Ray³

2019

IJMMM

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This paper presents an experimental investigation to study the influence of ultrasonic machining (USM) parameters (such as slurry concentration, power and feed rate) on material removal rate, taper angle and over-cut during the machining of zirconia (ZrO 2) composite. The experiments are conducted on the basis of Taguchi (L 9) orthogonal array and multi-objective optimisation on basis of ratio analysis (MOORA) is applied for optimisation of USM process parameters. Parametric analysis is also carried out to study the effect of each process parameters on the responses. Moreover, surface quality of the machined surface is analysed using optimal microscope images. In addition, empirical models are developed for optimum prediction of responses using regression analysis. Finally, confirmatory tests are performed to verify results with experimental results. The result shows that, the material removal rate is influenced by feed rate, and the taper angle and over-cut are influenced by slurry concentration. Also, optimisation method provides optimum parameter setting for USM process that satisfies the real need for machining of ZrO 2 composite in practice.

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“…Experimental investigations have been conducted for revealing the influences of abrasive size, abrasive material, and abrasive concentration in previous studies. [9][10][11] However, a complete understanding of their roles is still not clear due to the complexity of USM process. Considering that arguments on the abrasive shape have rarely been referred, both SPH simulations and experiments were conducted to study the influence of the abrasive type including its material and shape on USM in this study.…”

Section: Introductionmentioning

confidence: 99%

Smoothed particle hydrodynamics simulation and experimental study of ultrasonic machining

Wang

Shimada

et al. 2017

Proceedings of the Institution of Mechanical Engineers, Part B:

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Hard and brittle materials like glass and ceramics are highly demanded in modern manufacturing industries. However, their superior physical and mechanical properties lead to high cost of machining. Ultrasonic machining has been regarded as one of the most suitable fabrication techniques for these kinds of materials. A smoothed particle hydrodynamics model was proposed to study the material removal mechanism of the ultrasonic machining in this study. Influences of abrasive materials and the particle shapes on the crack formation of work substrates were investigated using this smoothed particle hydrodynamics model. Experiments were also conducted to verify the simulation model. Both of the simulation and experimental results show that using hard and spherical abrasive particles is helpful to improve the material removal efficiency. This work was the first to demonstrate the crack formation mechanisms during ultrasonic machining with different abrasive particles using smoothed particle hydrodynamics, which is significant for improving the machining performance of the ultrasonic machining process.

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Effect of process parameters on MRR, TWR and surface topography in ultrasonic machining of alumina–zirconia ceramic composite

Cited by 41 publications

References 14 publications

Novel Optimization Approach in Ultrasonic Machining: Unilateral Compensation for Resonant Vibration in Primary Side

Novel Optimization Approach in Ultrasonic Machining: Unilateral Compensation for Resonant Vibration in Primary Side

Experimental investigation and optimisation of ultrasonic machining parameters on zirconia composite

Smoothed particle hydrodynamics simulation and experimental study of ultrasonic machining

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