Optimization of Process Parameters for Surface Roughness in Ultrasonic Machining of Polycarbonate Bullet Proof Glass and Acrylic Heat Resistant Glass by Taguchi and Grey Relational Analysis Approach

Abstract

Polycarbonate bullet proof glass and acrylic heat resistant glass are used as the functional material in many application. In this research paper, Taguchi modal is utilized for the ultrasonic machining of these material. Surface roughness is significant output parameter, because it define accuracy of the process. Taguchi modal suggest that 40% concentration, mixture of Alumina, Silicon carbide and Boron carbide abrasive in 1:1:1, 600 abrasive grit size and 1.5% HF acid gives best results in polycarbonate bullet proof glass material and for acrylic heat resistant glass, mixture of Silicon carbide and Boron Carbide abrasive in 1:1, 600 abrasive grit size and 1% HF acid gives the best results. More significant parameters contribution in surface roughness are concentration of slurry, grit size of abrasive and HF acid. Optimum parameters improved the surface roughness by 23% and 24% in polycarbonate bullet proof glass and acrylic heat resistant glass respectively.