Abstract
The present investigation reports on reduction of width overcut (WOC) and edge chipping in micro-channels developed by rotary tool micro-ultrasonic machining using helical grooved tool. The experiments were conducted to evaluate the effectiveness of the helical grooved tool in terms of WOC and edge chipping. The tool rotation speed, work feed rate, power rating and abrasive size were selected as variable parameters. The results showed that the tool with helical grooved tool assisted the abrasives to replenish from machining zone, thereby reducing the WOC and edge chipping. Both very low and very high tool rotation speed, work feed rate, abrasive mesh size and low power rating resulted in lower WOC and edge chipping. The parametric combination of tool rotation speed 300 rpm, workpiece feed rate 20 mm/min, power rating 40% and abrasive mesh size #1200 resulted in lowest WOC and edge chipping and hence better form accuracy.
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