Machining optimization in rotary ultrasonic drilling of BK-7 through response surface methodology using desirability approach

Kumar, Vikas; Singh, Hari

doi:10.1007/s40430-017-0953-z

Cited by 18 publications

(11 citation statements)

References 51 publications

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“…A desirability function approach postulated by Harrington and later revitalized by Derringer and Suich was used to accomplish this objective [35,36]. This approach is commonly used to optimize the multiple output responses simultaneously [37][38][39][40][41]. In this approach, each of the response variable y i is normalized to a desirability value d i which lies in between 0 and 1.…”

Section: Multi-response Optimization Of Rt-musm Process With Wc Toolmentioning

confidence: 99%

Effect of tool materials on performance of rotary tool micro-USM process during fabrication of microchannels

Kumar

Dvivedi

2019

J Braz. Soc. Mech. Sci. Eng.

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The tool wear affects the efficiency of micro-USM process and the quality of machined micro-features. In this research endeavor, wear mechanism of soft/ductile and hard/brittle tool materials is investigated comprehensively. Stainless steel-304 (SS-304) and tungsten carbide (WC) were selected as tool materials for rotary tool micro-USM (RT-MUSM) process. The effect of tool material properties on tool wear and performance of RT-MUSM process is also discussed. The effect of RT-MUSM process parameters, viz. rotation speed, feed rate, power rating and slurry concentration on material removal rate (MRR), depth of channel (DOC) and width over cut (WOC) are reported. The experimental results showed that SS-304 tool worn out rapidly due to plastic deformation followed by strain hardening. The superior properties of WC such as high wear resistance, compressive strength and good acoustic property led to reduction in tool wear and thereby significantly improved the performance of RT-MUSM. Additionally, multi-response optimization was applied to obtain maximum MRR, DOC and minimum WOC simultaneously.

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Section: Multi-response Optimization Of Rt-musm Process With Wc Toolmentioning

confidence: 99%

Effect of tool materials on performance of rotary tool micro-USM process during fabrication of microchannels

Kumar

Dvivedi

2019

J Braz. Soc. Mech. Sci. Eng.

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“…The method of ultrasonic depends on the abrasion phenomenon. Blows from the grains of the harder abrasion, brittle materials are removed [4][5][6]. Abrasion phenomenon is under curb of the tool, which regularly vibrates with low amplitude (5-75 µm) and feed [1].…”

Section: Introductionmentioning

confidence: 99%

Design of Bezier profile horns by using optimization for high amplification

Kumar

Yadava

Patel

2020

J Braz. Soc. Mech. Sci. Eng.

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Rotary ultrasonic machine (RUSM) has a lot of applications in industries, with the recent uses of stronger and harder materials. Machining performance of RUSM depends on the design of the horn. A horn also known as a tool holder or concentrator is a waveguide focusing device, which has a decreasing area of the cross section from the upper to lower end. In RUSM, the high amplification factor of the horn is required to increase tooltip vibration for getting a high material removal rate. In this study, the design of the horn using an optimization procedure and finite element analysis (FEA) has been done. FEA-based MATLAB code has been developed for finding all the stress components, axial amplitude, and resonance frequency. Results are validated from the experimental data available in the literature, and it has been found that it is in good agreement with the literature. The amplifications of the horns with cubic and quadratic profiles 23.8% and 19%, respectively, are higher than the traditional horn with the same length and diameters of the ends. Stresses at different locations have been found within the allowable endurance limit. The effect of frequency on the stress distribution has also been studied and found that the variation of stresses over the domain of horn increases with an increase in frequency, but the value of stress is much lower at the resonance frequency.

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“…Results showed that the low feed rate, an adequate amount of amplitude as well as high cutting speed were selected as optimal parameters which result in decreasing the tool wear and exit crack of the drilled holes as 16.891 μm and 25.375 μm, respectively. Feed rate was found to be the most significant factor affecting the MRR and surface roughness of the holes drilled in BK7 glass using RUM [ 35 ].…”

Section: Introductionmentioning

confidence: 99%

Multi-Response Optimization of Processing Parameters for Micro-Pockets on Alumina Bioceramic Using Rotary Ultrasonic Machining

et al. 2020

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The machining of ceramic materials is challenging and often impossible to realize with conventional machining tools. In various manufacturing applications, rotary ultrasonic milling (RUM) shows strengths, in particular for the development of high-quality micro-features in ceramic materials. The main variables that influence the performance and price of the product are surface roughness, edge chipping (EC), and material removal rate (MRR) during the processing of ceramics. RUM has been considered in this research for the milling of micro-pockets in bioceramic alumina (Al2O3). Response surface methodology in the context of a central composite design (CCD) is being used to plan the experiments. The impacts of important RUM input parameters concerning cutting speed, feed rate, depth of cut, frequency, and amplitude have been explored on the surface roughness in terms of arithmetic mean value (Ra), the EC, and the MRR of the machined pockets. The main effect and the interaction effect of the implemented RUM parameters show that by providing a lower feed rate and cutting depth levels and elevated frequency and cutting speed, the Ra and the EC can be minimized. At greater levels of feed rate and cutting depth, higher MRR can be obtained. The influence of RUM input parameters on the surface morphology was also recorded and analyzed using scanning electron microscopic (SEM) images. The study of the energy dispersive spectroscopy (EDS) shows that there is no modification in the alumina bioceramic material. Additionally, a multi-response optimization method has been applied by employing a desirability approach with the core objectives of minimizing the EC and Ra and maximizing the MRR of the milled pockets. The obtained experimental values for Ra, EC, and MRR at an optimized parametric setting were 0.301 µm, 12.45 µm, and 0.873 mm3/min respectively with a combined desirability index value of 0.73.

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Machining optimization in rotary ultrasonic drilling of BK-7 through response surface methodology using desirability approach

Cited by 18 publications

References 51 publications

Effect of tool materials on performance of rotary tool micro-USM process during fabrication of microchannels

Effect of tool materials on performance of rotary tool micro-USM process during fabrication of microchannels

Design of Bezier profile horns by using optimization for high amplification

Multi-Response Optimization of Processing Parameters for Micro-Pockets on Alumina Bioceramic Using Rotary Ultrasonic Machining

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