Analysis of Material Removal Rate and Surface Roughness on Advanced Ceramics Materials Micro-Hole Drilling

Abstract

This study discussed the rotary ultrasonic machining (RUM) parameters and tool geometry parameters of optimized hole wall quality, and obtained better and uniformly distributed surface roughness of deep hole walls. The experimental configuration of this study was planned using Taguchi orthogonal array, where the hole diameter, spindle speed, feed rate and power were taken as the experimental factors. Drilling machining experiment was carried out using the parameter combination configured by the experimental design, and wall surface roughness of the drilled holes was measured. A relation model between the average surface roughness and standard deviation of the hole walls and processing parameters and tool geometry were established, so as to achieve optimized surface roughness of the overall deep hole walls. The optimization process respectively aimed at the minimum surface roughness and maximum metal removal rate. The experimental results proved that application of the optimized parameter combination in rotary ultrasonic machining of hole processing can obtain better and more uniform hole wall surface quality.The effect of control factors on the hole quality was discussed from the respects of the straightness deviation, minimum surface roughness and maximum metal removal rate of related factors on the hole when the Taguchi method was applied to rotary ultrasonic machining of hole drilling. The results showed that the level of straightness factors of produced holes can be fully presented. Keywords-Advanced Ceramics; Rotary Ultrasonic Machining; Surface Roughness; Material Removal Rate; Holes Deviation; Taguchi Method