Abstract
Metal matrix is highly acceptable composites providing good strength for industrial use. In many field of industries, especially aerospace industry metal matrix composites of type Al/SiC is used because of its superior properties. In this research work, experimentalanalysis has been done for producing through hole on metal matrix composites with suitable quality ultrasonic machining (USM) process. Three unconstrained process parameters are chosen, like abrasive slurry concentration, power rating sand tool feed rate. Material removal rate (MRR) is considered as response parameter. The effects of each parameter have been analyzed here. Analysis of variance (ANOVA) has also been applied to identify the most significant factor. Response surface methodology (RSM) has been utilized to developed empirical model for determine the performance of ultrasonic process. Optimization technique has been used to find out the maximum process MRR. Confirmation verification test has been done to improve optimal parametric condition for getting maximum MRR. This research paper gives viability application of USM process for producing of through hole on metal matrix composites and various applications in industry.
Highlights
Physical or chemical properties of work piece does not affect by keeping the whole microstructure unchanged during Ultrasonic machining (USM)
The mechanism of ultrasonic machining (USM) is based on electric current at given amplitude that fits within the field of ultrasounds which is converted electrical into mechanical vibration that is transferred to a machining tool
The result shows that some process parameters like abrasive grit size, power rating, and slurry concentration are most important to achieve a better material removal rate and good accuracy [21]
Summary
Physical or chemical properties of work piece does not affect by keeping the whole microstructure unchanged during Ultrasonic machining (USM). The material removal rate of USM depends on four parameters: such as slurry, work piece, tool, and machine-related factors. Hard and brittle materials are not machined in the traditional machining process that is why USM is used. Like other machining processes USM does not heatedthe work piece surface. While machining in USM it was found that work piece tool long time for machining with high value of toughness. Too wear is more when materials have high hardness and toughness where as tool wear is less for softer and brittle work materials [8]. Scratch grooves deformation characteristics of ductile and brittle materials are obtained It disclosed that increase material removal proportion, reduced scratch loads, and effectively inhibit small crack generation when during ultrasonic vibration occurred [11]. Ultrasonic assisted vibration test surface of work piece samples are damage and concluded that by the
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