Parametric optimization in Rotary Ultrasonic Drilling of BK7 through RSM based PSO

Abstract

This paper aims to establish the rotary ultrasonic machining as a pragmatic solution to tackle the machinability issues with brittle materials. In the present article, drilling variant of rotary ultrasonic has been used to machine the optical glass BK7 owing to its numerous applications in manufacturing sector. Experimental matrix has been designed by utilizing the response surface methodology after scrutinizing the machining variables (feed rate, spindle speed and ultrasonic power) through single variable at a time approach. Material removal rate (MRR) and surface roughness (SR) have been chosen as responses for assessing drilling performance. Thereafter ANOVA analysis was done at 95 % confidence level for figuring out the significant model terms (linear, interaction and square) that affect the responses of interest. Feed rate was found to have profound impact over the machining performance. Thereafter, desirability approach and particle swarm optimization (PSO) were used for yielding the right combination of input factors for concurrent optimization of responses. In comparison to desirability, particle swarm optimization (PSO) provided the instant optimal solutions to meet the industrial requirements. Further, confirmation experiments validated the accuracy of desirability and PSO to predict the optimal solution with little errors.