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International Conference on Mechanical and Electrical Technology, 3rd, (ICMET-China 2011), Volumes 1–3

Yi Xie
Yi Xie
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High hardness, Lack of ductility, and low resistance to thermal shock, often result in low material removal rate and subsurface damage, which may lead to a spontaneous fracture during machining for engineering ceramics. Ultrasonic machining is a mechanical material removal method that is appropriate to create holes in hard and brittle materials by means of an ultrasonically vibrating properly-shaped tool and abrasive slurry. In this article modal analysis is used to choose the best shape for wave transfer which is called horn. A desktop CNC milling machine is used to create feed motion on ultrasonic head. Effects of input factors: power, abrasive grit size, slurry concentration and feed rate are analyzed by Taguchi method on the material removal rate (MRR), tool wear rate (TWR) and hole over size (HOS). The results imply that among input parameters, power has the most effect on MRR, also grit size and feed rate have the most effects on TWR and HOS.

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