Rotary ultrasonic machining of advance materials: A review

Abstract

With its superior machining quality, rotary ultrasonic machining (RUSM) is the best alternative to machine complex, brittle materials like ceramics, glass, composites, and quartz. These materials are complex to machine with the conventional process. Other advanced materials during ultrasonic machining also result in poor machining characteristics. To achieve fine machining, hole accuracy was primarily focused on hard-to-cut materials like ceramics regarding deep drilling of holes. Hybrid machining is one of the best methods for RUSM to experience these challenges. The main objective of this review paper was to identify the different machining variables of rotary ultrasonic machining and their influence on the output response variables such as material removal rate (MRR), tool wear rate (TWR), and surface roughness (S.F.), etc., considered especially for different glass composites. In rotary ultrasonic machining, a review of the material removal methods, a description of the operation, the rate of material removal, and problems with tool wear are discussed. Based on the literature studied, the experimental results obtained for machining of advanced materials such as composites, silicon, advanced glass, CFRP, titanium, and carbides, etc., on RUSM, the various input parameters were analyzed to figure out the effect on output responses critically. Future research in rotary ultrasonic machining should optimize output responses such as cutting force, chipping size, hole cylindricity, and tool wear using advanced optimization techniques.