An experimental study on ultrasonic machining of pure titanium. Experimental study of micro electrochemical discharge. Request pdf experimental study of micro ultrasonic machining process this paper presents the results of micro ultrasonic machining using oil based abrasive slurry. The aim of this paper is to present experimental work that has been done in micro holes machining by micro usm. Smoothed particle hydrodynamics simulation and experimental.
Request pdf experimental study of tool wear in micro ultrasonic machining tool wear in micro ultrasonic machining usm affects the accuracy of a machined feature. In this paper, a new process method, named horizontal ultrasonic edm huedm, is proposed. Surface grinding of optical bk7k9 glass using rotary. In order to do so, a setup for imparting ultrasonic vibration to workpiece is developed and experiments have been performed to study the effect of edm input parameters and ultrasonic vibrations on process performance of edm. This article presents an experimental study of a recently developed process, namely, ultrasonic assisted jet electrochemical microdrilling uajetecmd using pulsed dc voltage power supply. The surface finish achieved by a single machining process no finishing. In micro ultrasonic machining musm, a major part of the material is removed by the impact of abrasive particles. Ultrasonic machining is a contemporary manufacturing method usually employed for processing materials with higher hardnessbrittleness such as quartz, semiconductor materials, ceramics etc. Enhancement of surface quality and study on material removal mechanism in micro ultrasonic machining. This is fed to the piezoelectric transducer located in the ultrasonic spindle. Micro ultrasonic machining microusm is an unconventional micromachining technology that has capability to fabricate high aspect ratio microholes, intricate shapes and features on various hard and brittle materials. Surface roughness prediction in rotary ultrasonic machining.
It is necessary to drill micro holes in some hard brittle materials. Experimental setup most past efforts have been spent on studying the mechanisms of ecdm. In this study, an inhouse fabricated sawjm setup is used to machine a stack of carbon fiber reinforced polymer cfrp and titanium. During the machining process, the motion trail of a single diamond grain in rum is a sine curve, thanks to ultrasonic vibration.
Nov 11, 2017 the study found that micro ultrasonic machining process is capable of successfully micromachining cfrpti stacks. As a micro mechanical machining process, micro ultrasonic machining micro usm has the major advantage of producing microscale components or features in brittle glass, quartz crystal, and sapphire and hard ceramics materials. The relevant experimental results indicate that the erosion depth and the. In the present paper, an experimental study of the ultrasonicbased depassivation process and its benefits related to an ecm proces are presented and discussed. Ultrasonic machining usm could be another alternative machining process that can be applied commercially to the machining of titanium. Micro ultrasonic machining micro usm is an unconventional micromachining technology that has capability to fabricate high aspect ratio micro holes, intricate shapes and features on various hard and brittle materials. Carbon fiberreinforced plastic cfrp composite is one of the most sought after material owing to its superior physical and mechanical properties such as high durability and high strengthtoweight ratio. High resolution micro ultrasonic machining for trimming 3d. Usm process aims for low machining rates, providing high resolution and high surface quality. As the tool continues to move downwards, the force acting on these grits increases rapidly, therefore some of the grits may be fractured.
Experimental study on micromachining of cfrpti stacks. Proceedings of the asme 2017 12th international manufacturing science and engineering conference collocated with the jsmeasme 2017 6th international conference on materials and processing. Parametric study of micro ultrasonic machining process of. Experimental study on horizontal ultrasonic electrical. Jun 03, 2014 principle of ultrasonic machining in the machining process, the tool, at some point, impacts on the largest grits, which are forced into the tool and workpiece. Experimental results show that the tool shape remains unchanged and the tool. It is a promising solution for machining of hard and bri ttle materials.
Therefore, it is important to use machining processes that minimize surface microcracks 4. Surface grinding of optical bk7k9 glass using rotary ultrasonic machining. However, the tool wear in microultrasonic machining adversely affects the machining accuracy. The goal of the work was to examine the effect of pulsed dc voltage on the performance of uajetecmd process. Illustrations of rotary ultrasonic machining rum and microscopic pictures of machined surface, cutting interface, and cutting chips of k9 glass. In the experiments, polycrystalline diamond particles ranging. Basics of ecm process electrochemical machining ecm for conductive. A new nontraditional machining method using cavitation. Usm process could successfully machine hybrid composite stacks at micron scale with a relatively good surface finish. Introduction micro ultrasonic machining micro usm, is one of the efficient material removal processes especially suitable for the micromachining of hard. Power ultrasonic vibration honing technology is more systematically studied from the kinematics point of view in this paper. Principle of ultrasonic machining in the machining process, the tool, at some point, impacts on the largest grits, which are forced into the tool and workpiece. Ultrasonic machining is a nontraditional process, in which abrasives contained in a slurry are driven against the work by a tool oscillating at low amplitude 25100 microns and high frequency 1530 khz. In this study, an inhouse fabricated sawjm setup is used to machine a stack of.
Facing to these challenges, an efficient and effective rotary ultrasonic machining rum process, consisting of grinding process and ultrasonic machining process, was provided to process bk7k9 glass. The flow rate of the abrasive slurry was maintained constant. And, the ultrasonic vibration is activated on the abrasive waterjet nozzle. Studying the effects of experimental parameters requires many experiments. Despite some developments in microusm process, issues such as precision measurement and control of the machining force, which is crucial for stable machining conditions, need further investigations. Rotary ultrasonic machining of optical k9 glass using. Hydrodynamic cavitation machining hcm, and ultrasonic cavitation machining ucm, they will be introduced, and the parameters associated with them will be presented. Development and experimental study of ultrasonic assisted electrical discharge machining process. Downscaling of rum for micro scale machining is essential to generate miniature features or parts from hard and brittle materials. Usm is mechanical material removal process or an abrasive process used to erode holes or cavities on hard or brittle workpiece by using shaped tools, high frequency mechanical motion and an abrasive slurry. Results for experiments with electroplated abrasive tools. Experimental study on machining of hybrid composite stacks. An experimental study on ultrasonic machining of tungsten. Development and experimental study of ultrasonic assisted.
Pdf enhancement of surface quality and study on material. A new nontraditional machining method using cavitation process. Experimental study of tool wear in micro ultrasonic machining. Ultrasonic machining process is an abrasive process and material removal is purely mechanical. This paper presents a study on fabrication of 3 d stepped microchannel. Micro ultrasonic machining micro usm, is one of the efficient material removal processes especially suitable for the micromachining of hard and brittle materials. To control the quality of micro holes fabricated in hard and brittle materials, musm with force control musmfc is used to study the edge chipping rate ecr and material removal. His current research activities include analysis and modelling of silicon wafering processes and traditional and nontraditional machining processes. This volume presents research papers on unconventional machining also known as nontraditional machining and advanced manufacturing and composites which were presented during the 7th international and 28th all india manufacturing technology, design and research conference 2018 aimtdr 2018. Request pdf study of 3d microultrasonic machining many manufacturing. The ultrasonic transducer converts electrical input into mechanical vibrations. The main machining mechanisms of usm are discussed.
Experimental study on high frequency chatter attenuation. A smoothed particle hydrodynamics model was proposed to study the material removal mechanism of the ultrasonic machining in this study. The vibrationassisted edm can be applied to from micro edm to macro edm, and the present study focuses on the mechanism of ultrasonic vibrationassisted edm, and expects to make it useful in micro edm and precision edm. An experimental study on ultrasonic machining of an. Non traditional machining jagadeesha t, assistant professor, med, national institute of technology, calicut ultrasonic machining definition. The research involves experimental study on precision machining of hybrid composite stacks using submerged abrasive waterjet machining sawjm process. An experimental study on ultrasonic machining of j. Micro ultrasonic machining musm is an effective way of processing microstructures made from hard and brittle materials, although controlling the fluctuation of the machining force during processing is difficult. An experimental study on ultrasonic machining of pure. Ultrasonic machining usm offers an attractive alternative to machine some of the hard and brittle materials.
It is clear from the experimental results that ultrasonic assisted micro edm has the potential for deep hole drilling. Usm offers a solution to the expanding need for machining. Rotary ultrasonic machining rum is one process capable of machining these materials. Micro ultrasonic machining microusm is a process with a great capability to generate micro features in hard and brittle materials. In the early stage of machining, abrasive particles are distributed uniformly in the machining area. Experimental study on high frequency chatter attenuation in 2. In this paper, an attempt has been made to combine the electrical discharge machining edm with ultrasonic machining. This article presents an experimental study of a recently developed process, namely, ultrasonic assisted jet electrochemical micro drilling uajetecmd using pulsed dc voltage power supply. Pdf an experimental study on ultrasonic machining of tungsten. Many manufacturing processes, such as lithography, etching, laser electrical. Optimization and modelling of process parameters involved. Intermittent and continuous rotary ultrasonic machining of k9. The material removal in usm is based on brittle fracture of work materials. Study of micro rotary ultrasonic machining aarati sarwade university of nebraska at lincoln, sarwade.
The gardening channel with james prigioni recommended for you. Experimental study of micro holes machining by usm. However, as the process goes on, abrasive particles will be driven out of the machining area owing to the ultrasonic vibration of the micro tool or workpiece and the rotation of. Pdf experimental study of micro ultrasonic machining process. Pdf in current study, the effects of numerous process parameters such as properties of. Sep 01, 2015 ultrasonic machining is an abrasive process which can create any material into hard and brittle form with the help of its vibrating tool and the indirect passage of abrasive particles towards the work piece. The rotary ultrasonic machining process rum for the processing of advanced ceramics is one of the costeffective machinery processes. Experimental investigation of electrochemical micro. The flexibility to machine 3 d complex geometries has been reported by several researchers 11, 12. However, the tool wear in micro ultrasonic machining adversely affects the machining accuracy. Processing capabilities of micro ultrasonic machining for.
Recent development on ultrasonic micro machining usmm process has been highlighted and discussed in details with different types of ultrasonic micro machining usmm set up and material removal. On performance evaluation of helical grooved tool during rotary tool microultrasonic machining. Experimental investigation of electrochemical micro machining process parameters on ti6al4v by using simulated annealing p. Micro ultrasonic machining micro usm is a nontraditional micro machining process. The flow rate of the abrasive slurry was maintained constant at a value of 36. An aspect ratio of 20 has been achieved in the machining of micro holes in austenitic stainless steel in this study.
Usm is a manufacturing process capable of machining such difficulttomachine materials with ultraprecision. However, their superior physical and mechanical properties lead to high cost of machining. Materials such as silicon, glass, quartz crystal, and ceramics are being increasingly used in microelectromechanical system mems devices. Rum is a hybrid machining process which combines the mechanism of material removal of conventional grinding and ultrasonic machining. Ultrasonic enhancement of an electrochemical machining. Experimental setup and model for machining process 2. Ultrasonic machining is an abrasive process which can create any material into hard and brittle form with the help of its vibrating tool and the indirect passage of abrasive particles towards the work piece. And there are only simple theoretical introductions, which have not formed the systematic theory. The experimental and the theoretical results exhibited a matching trend. Intermittent and continuous rotary ultrasonic machining of. The machined surface produced by ultrasonic machining is found to be free from any surface defects heat affected zone, cracks, recast layer, etc. The relevant experimental results indicate that the erosion depth and the material. The machining characteristics that are being investigated are tool wear rate and the quality of the.
Advances in unconventional machining and composites. The vibrationassisted edm can be applied to from microedm to macro edm, and the present study focuses on the mechanism of ultrasonic vibrationassisted edm, and expects to make it useful in microedm and precision edm. The rotary ultrasonic machining process rum for the processing of advanced ceramics is one of the costeffective. Ultrasonic machining usm could be another alternative machining process that.
Experimental study on micromachining of cfrpti stacks using. Nov 23, 2019 in this paper, an attempt has been made to combine the electrical discharge machining edm with ultrasonic machining. The quality of the flow is improved, and the velocity of the abrasive is increased because of the addition of the ultrasonic energy. Ultrasonic machining, or strictly speaking the ultrasonic vibration machining, is a subtraction manufacturing process that removes material from the surface of a part through high frequency, low amplitude vibrations of a tool against the material surface in the presence of fine abrasive particles. This paper reports on the evaluation of a high resolution micro ultrasonic machining hr. Experimental investigations and statistical modeling of. Rotary ultrasonic machining rum, a nontraditional machining process, is a hybrid process that combines the. However, as the process goes on, abrasive particles will be driven out of the machining area owing to the ultrasonic vibration of the microtool. Comparing with electro discharge machining, electrochemical machining and laser machining, the ultrasonic machining usm has unique advantages in hard brittle materials machining. Experimental study of micro ultrasonic machining process.
Optimization and modelling of process parameters involved in. A study on the high aspect ratio micro hole drilling using. The ultrasonic vibration is used to enhance the capability of the abrasive water micromachining glass. Study of 3d microultrasonic machining research nebraska. Ultrasonic machining national institute of technology calicut. A comparative experimental investigation of grinding and rotary ultrasonic machining were made on borosilicate and zerodur materials to know the efficacy of rotary ultrasonic machining process over grinding for micro electromechanical system. Usm process suitable for post fabrication trimming of complex 3d microstructures made from fused silica. In comparison with conventional processes, micromachining of cfrpti stacks using micro ultrasonic machining process resulted almost zero cfrp delamination, minimal variation in cfrp and ti hole sizes, and longer tool life. In addition, a study on the electrolytic inprocess dressing grinding of optical glass showed that the electrolytic inprocess dressing grinding could be an effective ultraprecision grinding process for hard and brittle materials 8. Kinematics analysis and experimental study on ultrasonic. An experimental study on ultrasonic machining of pure titanium using designed experiments in the present research work, the effect of several process parameters on the machining characteristics of pure titanium astm gradei has been reported.
The study found that micro ultrasonic machining process is capable of successfully micromachining cfrpti stacks. Rotary ultrasonic machining rum is capable of machining these materials. Rotary type ultrasonic machining is a hybrid machining. Experimental study of micro ultrasonic machining process sreenidhi cherku, murali m sundaram, and k p rajurkar center for nontraditional manufacturing research university of nebraskalincoln lincoln, nebraska, usa introduction micro ultrasonic machining micro usm, is one of the efficient material removal processes especially suitable for the. Experimental study on micromachining of cfrpti stacks using micro ultrasonic machining process. The trail length in rum is much longer than that in ordinary grinding, which leads to a large increase in the effective contact time between the tool and the material. How to build a hinged hoophouse for a raised bed garden duration. Study of micro ultrasonic machining of silicon asme. This experimental study demonstrates that the 2d vibration assistance is able to effectively. However, most clinical failures initiate from the surface micro cracks. Rotary type ultrasonic machining is one of the costeffective machining processes available for drilling holes in advanced ceramics.
The tool travels vertically or orthogonal to the surface of the part at amplitudes of. It was shown that chatter was suppressed in ultrasonic vibration assisted machining process. Ultrasonic machining national institute of technology. Ultrasonic machining has been regarded as one of the most suitable fabrication techniques for these kinds of materials.
The performance characteristics such as material removal rate of machined samples using ultrasonic machining process have been presented. Experimental study of electrophoretically assisted microultrasonic. Experimental study of electrophoretically assisted micro. Experimental investigation into micro ultrasonic machining of quartz. Khamba, an experimental study on ultrasonic machining of pure titanium using designed experiments, journal of the brazilian society of mechanical sciences and engineering 30 3 2008 231238. The material removal in usm is based on brittle fracture of. Experimental study of the ultrasonic vibrationassisted. The current research of the ultrasonic vibration assisted machining technology focused on the experimental analysis. The experimental conditions were designed by using the design of experiments approach. Therefore, it is important to use machining processes that minimize surface micro cracks 4. Study of micro rotary ultrasonic machining unl digital commons.
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