An Experimental Investigation on Surface Roughness and Edge Chipping in Micro Ultrasonic Machining
محورهای موضوعی : Manufacturing process monitoring and control
Hamid Zarepour
1
(Department of Mechanical Engineering, Najafabad Branch, Islamic Azad University, Najafabad, Iran|Modern Manufacturing Technologies Research Center (MMTRC), Najafabad Branch, Islamic Azad University, Najafabad, Iran)
کلید واژه: Experimental Design, Micro Ultrasonic Machining, Surface Quality, Edge Chipping, Process Parameters,
چکیده مقاله :
Surface quality including surface roughness and edge chipping is a key process measure in microultrasonic machining (Micro-USM) as an efficient process for micromachining of hard and brittlematerials. Process parameters such as ultrasonic vibration amplitude, static load, type of toolmaterial, type and size of abrasive particles and slurry concentration can influence the surfacequality. However, there is limited study on the parametric effects on the surface quality in micro-USM. The objective of this study is to investigate the effects of the workpiece material as well asprocess parameters including abrasive type, particle size and vibration amplitude on surfaceroughness and edge chipping in micro-USM. Silicon, alumina ceramics and soda-lime glass wereselected as workpiece materials and polycrystalline diamond and alumina as abrasives. Particle sizeranging from 0.3 to 3 μm and vibration amplitude ranging from 0.8 to 3 μm were selected in thisstudy. Results indicate that workpiece material and vibration amplitude have significant effects onsurface roughness. Workpiece material was found to be the most significant parameter with apercentage contribution of about 45 % in the variation of mean Ra, followed by vibration amplitudeand particle size of about 28 % and 5% contributions, respectively. Results also show that aluminaceramic is a material capable of achieving better surface quality in micro-USM as compared tosilicon and soda-lime glass.
