Grey Relational Analysis of Chemical Assisted USM of Polycarbonate Bullet Proof (UL-752) & Acrylic Heat Resistant (BS-476) Glass

Abstract

This paper is developed an innovative process of chemical assisted ultrasonic machining of polycarbonate bullet proof UL-752 and acrylic heat resistant BG-476 glass and conduct an investigation for optimize the machining parameters associated with multiple performance characteristics using Grey relational analysis. Machining of polycarbonate bullet proof UL-752 and acrylic heat resistant BS-476 glass are difficult process via conventional machining, however, it can be easily machined by Ultrasonic machining. Carefully selected parameters gives the optimum results. In this experimental work input parameters abrasive slurry concentration, type of abrasive, power rate, grit size of abrasive particles, hydro-fluoride acid concentration and tool material are selected. The effect of input parameters viz material removal rate, tool wear rate and surface roughness are investigate. Grey relational analysis and analysis of variance are performed to optimize the input parameters and better output results. In PBPG UL-752, increment in material removal rate by 75.58%, tool wear rate by 45.34% and surface roughness by 34.18%. In other hand, in AHRG BS-476, increment in material removal rate by 61.24%, tool wear rate by 31.46% and surface roughness by 23.85%. The surface topography is investigate through SEM images. It also observed that HF acid have the significant role in surface roughness. It also reduce the micro cracks on machined zone. Harder tool and harder abrasive slutty gives the higher material removal rate, but it also enhance the tool wear rate.