Modeling of Material Removal Rate and Hole Circularity on Soda–Lime Glass for Ultrasonic Drilling

Abstract

Soda–lime glass possesses high hardness and brittleness. Analysis of machining of soda–lime glass becomes essential as it is now being extensively used material for different engineering and medical purposes. The intrinsic characteristics of soda–lime glass make it difficult to machine materials. In this study, experimental modeling for material removal rate (MRR) and hole circularity has been performed using the response surface methodology (RSM) for ultrasonic drilling (USD) of 2 mm diameter hole in 3 mm thick soda–lime glass. The effect of input process parameters like ultrasonic power, frequency, and abrasive grit number has been analyzed on MRR and hole circularity. It was experiential that the effect of ultrasonic power on both MRR and hole circularity for different grit size is not very important. Abrasive with high grit number rises the MRR but declines the MRR after initial rise up to grit number of 40. At a specific ultrasonic power, the increase of frequency continuously increases the hole circularity, but in case of MRR, it begins to decrease after 23 kHz. The result of ultrasonic power on both MRR and hole circularity is nonlinear gradual decline up to 80 W further increase later.