Statistical Analysis of Experimental Parameters in Ultrasonic Machining of Tungsten Carbide Using the Taguchi Approach

Abstract

The objective of this paper is to study the influence of operating parameters of ultrasonic machining of tungsten carbide on the machining characteristics. The effectiveness of the ultrasonic machining process with tungsten carbide is evaluated in terms of the material removal rate and the surface finish quality of the work piece produced. Tungsten carbide as a super hard and high wear‐resistant material has been used widely in industries. Powder metallurgy technology is the common method for producing tungsten carbide components. However, this method is obviously too costly and time consuming for small quantity production, such as product prototyping. It is expected to make the prototypes by a material removal process, such as ultrasonic machining. In this paper, an experimental study on the ultrasonic machining of tungsten carbide is presented using a systematic approach. Practical aspects are given on the characteristics of tungsten carbide as functions of the type of abrasive slurry, their size and concentration, nature of the tool material, and the power rating of the machine. The optimum combination of various input factors for the ductile chip formation in the machining of tungsten carbide has been determined by applying the Taguchi approach and the F‐test.