Full factorial optimization of process parameters for MRR during Ultrasonic Machining of Alumina- Ceramic

  • Dr. Y. Rama Mohan Reddy, Mr. B. Subba Reddy


Ultrasonic machining (USM) is a mechanical material expulsion process used to disintegrate openings and depressions in hard or fragile work pieces by utilizing formed instruments, high-recurrence mechanical movement and a rough slurry. Dissimilar to other non-conventional machining forms, for example, laser bar and electrical release machining, USM process does not thermally harm the work piece or present huge levels of leftover pressure, which is imperative for survival of materials in benefit. For having upgraded machining execution and better machined work attributes, it is regularly required to decide the ideal control parameter settings of a USM procedure. The prior scientific methodologies for parametric improvement of USM forms have for the most part yielded close ideal or problematic arrangements. In this paper, the objective considered is maximization of material removal rate (MRR) subjected to the constraint of surface roughness. The process variables considered for optimization are Power rating, static load, Abrasive size, Slurry concentration. The amplitude of ultrasonic vibration, frequency of ultrasonic vibration, and static feed force are kept constant. This paper develops a predictive and optimization model by Factorial approach (FA) and general factorial Regression analysis . The material used for the machining is alumina ceramics.