Multi-objective Optimization of Rotary Ultrasonic Machining Parameters for Quartz Glass Using Taguchi-Grey Relational Analysis (GRA)

Abstract

Rotary ultrasonic machining has the capability to process the materials which are very hard, brittle and electrically non-conductive, with efficiency and cost-effectiveness. The current investigation is focused on the use of Taguchi-Grey relational analysis to improve the machining performance of Rotary ultrasonically machined quartz glass. Ideal machining parameters were calculated by grey relational grade calculated in grey relational analysis which was designed for simultaneous optimization of material removal rate and surface roughness. The rotary ultrasonic machining parameters setting with tool rotational speed of 5000 rpm, tool feedrate of 0.75 mm/min, and ultrasonic power of 55% were found to have the highest grey relation grade resulting in the high material removal rate and low surface roughness of the processed material. The tool feed rate was found to be the most critical parameter followed by ultrasonic power and tool rotational speed on the rotary ultrasonic machining characteristics. Confirmatory experiments were also executed to authenticate the forecasted results obtained from the Taguchi-Grey relational analysis. Furthermore, the microstructural investigation was carried out to comprehend the mechanism of material removal in the rotary ultrasonic machining of quartz glass at optimum parameter setting. It was found that the material was removed in the brittle mode and abrasion during the machining at optimum parameter setting. The sharp cutting edges of the diamond grits have caused the abrasive wear and brittle fracture of the quartz material. The interlinking of the cracks results in the pullout of the grains and consequently deeper grooves are formed on the machined surface.