Analysis of the effect of process parameters on material removal rate in ultrasonic machining

Ultrasonic Machining (USM) is best suited for machining brittle materials such as ceramics. The process has been successfully used to assist deburring, polishing, lapping, grinding, and drilling operations. Hardened steel, glass, ruby, and ceramics have been finish machined to achieve surface finish under one micron. This research develops a practical model for USM process and analyzes the effects of process parameters on the material removal rate (MRR).; The debris from the process, that include worn abrasives and removed work material, is inspected by a laser particle distribution analyzer. The models for the changes in abrasive shapes and particle distributions for the worn alumina and removed material are developed and verified by experiments. The models are used to describe the change in particle distribution over time. The methods for evaluation of the threshold fracture for brittle material and prediction of material removal volume of a single abrasive are found. A dynamic and stochastic model is built. The model makes it possible to predict the distribution of MRR and cutting depth. The predicted relations between MRR and the process variable agree fairly well with experimental results.; USM of alumina by boron carbide abrasives are tested to screen the significant effects on MRR and surface roughness. Feed rate was found as one of the important factors that can verify the dynamic character of MRR. The material removal for alumina does not only individually depend on ultrasonic vibration but also on feed rate. This research can be used to develop an intelligent USM manufacturing system.