Sandeep Singhal

Rotary Ultrasonic Machining: A Review

Rotary ultrasonic machining (RUM) is a mechanical type of nontraditional hybrid machining process that has been utilized potentially to machine a wide range of latest and difficult-to-machine materials, including ductile, hard and brittle, ceramics, composites, etc. In RUM, the basic material removal phenomenon of ultrasonic machining (USM) and conventional diamond grinding amalgamates together and results in higher material removal rate (MRR), improved hole accuracy with superior surface finish. In the current article, several investigations carried out in the domain of RUM for enormous materials have been critically reviewed and reported. It also highlights several experimental and theoretical ensues of RUM to improve the process outcomes and it is reported that process performance can be substantially improved by making the right selection of machine, diamond tooling, material and operating parameters. In recent years, various investigators have explored umpteen ways to enhance the RUM process performance by probing the different factors that influence the quality attributes. Among the various accessible modifications in RUM as employed in industries, rotary ultrasonic drilling is more strongly established compared to other versions such as rotary ultrasonic side milling, face milling, grinding, surface texturing, etc. The micro machining applications of RUM have also been discussed briefly. The final section of this paper discusses RUM developments and outlines the aspects for future research.

Investigation of machining characteristics in rotary ultrasonic machining of alumina ceramic

ABSTRACT Alumina ceramic is well documented as a much-demanded advanced ceramic in the present competitive structure of manufacturing and industrial applications owing to its excellent and superior properties. The current article aimed to experimentally investigate the influence of several process variables, namely: spindle speed, feed rate, coolant pressure, and ultrasonic power, on considered machining characteristics of interest, i.e., chipping size and material removal rate in the rotary ultrasonic machining of alumina ceramic. Response surface methodology has been employed in the form of a central composite rotatable design to design the experiments. Variance analysis testing has also been performed with a view to observing the consequence of the considered parameters. The microstructure of machined rod samples was evaluated and analyzed using a scanning electron microscope. This analysis has revealed and confirmed the presence of plastic deformation that caused removal of material along with brittle fractures in rotary ultrasonic machining of alumina ceramic. The validity and competence of the developed mathematical model have been verified with test results. The multi-response optimization of machining responses (material removal rate and chipping size) has also been attempted by employing a desirability approach, and at an optimized parametric setting the obtained experimental values for material removal rate and chipping size were 0.4166 mm3/s and 0.5134 mm, respectively, with a combined desirability index value of 0.849.

Rotary ultrasonic machining of macor ceramic: An experimental investigation and microstructure analysis

ABSTRACT Macor ceramic has been well recognized as a classic engineering material that possesses wide industrial usage owing to its excellent and versatile properties. However, its fruitful and productive processing is still unanswered. The present article attempts to experimentally investigate the influence of numerous process variables on machining characteristics in rotary ultrasonic machining of macor ceramic. The impact of different input factors, namely spindle speed, feed rate, coolant pressure, and ultrasonic power, has been evaluated on the process responses of interest, i.e., surface roughness (SR) and chipping thickness (CT). The experiments are designed by utilizing response surface methodology (RSM) through a central composite rotatable design. The variance analysis test was performed with a view to observe the significance of the considered parameters. Microstructure analysis of the machined samples revealed and confirmed the presence of dominating brittle fracture that caused the removal of material along with a slight plastic deformation of the work surface. The multi-response optimization of machining responses was carried out by utilizing the desirability approach. At optimized parametric setting, the obtained experimental values for SR and CT were found to be 0.523 µm and 0.156 mm, respectively.

An experimental study on rotary ultrasonic machining of Macor ceramic

Macor ceramic has been well recognized as an eminent engineering material which possesses enlarged industrial usage owing to its excellent and versatile properties. However, its fruitful and economic processing is still unanswered. This article has targeted to experimentally investigate the influence of numerous process variables on machining characteristics in rotary ultrasonic machining of Macor ceramic. The impact of different input factors, namely, spindle speed, feed rate, coolant pressure, and ultrasonic power has been appraised on process responses of interest, that is, material removal rate and chipping size. The experimental plan was designed by employing response surface methodology through central composite rotatable design. The variance analysis test has also been performed with a view to observe the significance of considered parameters. Microstructure of machined samples has also been evaluated and analyzed using scanning electron microscope. This analysis has revealed and confirmed the presence of dominated brittle fracture that caused removal of material along with the thin plastic deformation in rotary ultrasonic machining of Macor ceramic. The reliability and competence of the developed mathematical model have been established with test results. The multi-response optimization of machining responses has also been done by utilizing desirability approach, and at optimized parametric setting, the obtained experimental values for material removal rate and chipping size are 0.4762 mm3/s and 0.3718 mm, respectively, with the combined desirability index value of 0.937.

Experimental study on rotary ultrasonic machining of alumina ceramic: Microstructure analysis and multi-response optimization

Excellent and superior properties of alumina ceramic make it a one of the highly demanded advanced ceramics in the present competitive scenario of manufacturing and industrial applications. However, its effective and economic processing is still a challenge. The present article has targeted to experimentally investigate the influence of several process variables, namely spindle speed, feed rate, coolant pressure, and ultrasonic power on different machining performances, i.e. surface roughness, and chipping thickness. Response surface methodology has been employed to design the experiments. Microstructure of the machined samples has been evaluated and analyzed through scanning electron microscope. This analysis has revealed and confirmed the presence of plastic deformation of work surface that caused the material removal along with the dominated brittle fracture in the processing of alumina ceramic with rotary ultrasonic machining. The multi-response optimization of machining responses has been done by using desirability approach. At the optimized parametric setting, the obtained experimental values for surface roughness and chipping thickness are found to be 0.215 µm and 0.159 mm, respectively.

Experimental investigation of machining characteristics in rotary ultrasonic machining of quartz ceramic

Quartz ceramic has been well observed as one of the highly demanded advanced ceramics which is receiving enlarging industrial approbation owing to its excellent and superior properties. However, its fruitful processing with traditional and non-traditional machining methods is still a challenge. The current article has aimed to experimentally investigate the influence of several process variables, namely, spindle speed, feed rate, coolant pressure, and ultrasonic power on machining characteristics of interest, i.e. chipping size, and material removal rate in rotary ultrasonic machining of quartz ceramic. Response surface methodology has been employed to design the experiments and the variance analysis test has also been performed with a view to observe the significance of considered parameters. Microstructure of machined samples has also been evaluated and analyzed using scanning electron microscope. This analysis has revealed and confirmed the presence of dominating brittle fracture that caused removal of material along with the slighter plastic deformation in rotary ultrasonic machining of quartz ceramic. The soundness and competence of the developed mathematical model have been established with test results. The multi-response optimization of machining responses has also been done by utilizing desirability approach, and at optimized parametric setting, the obtained experimental values for material removal rate and chipping size are, 0.6437 mm3/s and 1.3326 mm, respectively, with the combined desirability index value of 0.949.

Comparative analysis of procedural approaches for facility layout design using AHP approach

The purpose of this paper is to apply multiple attribute decision-making (MADM) approach (analytic hierarchy process - AHP) for ranking the procedural approaches available for solving the facility layout design problems (FLPs). Analytic hierarchy process is applied to rank the approaches, whereas the weight to a factor is assigned using modified digital logic (MDL) method. On the basis of assigned weight the matrix is generated, and the factors considered for analysis are as: initial data required (IDR), use of charts (UC), use of graphs and diagrams (UG), future expansion considered (FE), constraints considered (CC), procedure implementation (PI), and material handling equipment selection considered (MH). The approaches which have been compared are as: Nadlers procedure (NP), Immers procedure (IP), Muthers procedure (MP), Apples procedure (AP), and Reeds procedure (RP). The results of the present study demonstrate that MP gets highest rank among the compared procedures. The output ranks along with their overall priority from the present study are as: MP (0.355) > AP (0.232) > RP (0.228) > NP (0.098) > IP (0.088). The factors which are used in this study are weighted in the order as: UC (0.22) > UG (0.195) > MH (0.171) > PI (0.146) > CC (0.098) = IDR (0.098) > FE (0.073).

A review of objectives and solution approaches for facility layout problems

Here, a review of the research papers on the facility layout problem is being presented. Various facility layout papers on meta-heuristic and the other approaches are summarised along with their objectives, solution approaches and their results thereof. The recent developments and future scope of facility layout problems have been considered and mapped in this research paper. In various research papers considered, a trend is observed that multiobjective approaches have been consciously considered for facility layout problems and design rectifications. The hybrid approach is found to be the most favoured and considered solution to current problems as well as initiating a systematic approach for future after due consideration of some specific objective functions which still need to be consider while designing future layouts.

Hybrid combination of Taguchi-GRA-PCA for optimization of wear behavior in AA6063/SiCp matrix composite

ABSTRACT The present work examined is centered on creation of aluminum alloy AA6063/SiCp metal matrix composites by liquid metallurgy stir casting route and optimization of wear properties by utilizing Taguchi-based GRA integrated with PCA approach. The AMCs are created in three diverse wt. % (3.5 wt %, 7 wt % and 10.5 wt %) of SiC reinforcement particles. The exploratory runs to examine the wear performance are executed as per L9 Taguchi plan to acquire the wear information in a controlled way. The wear loss data in terms of height loss are acquired using pin-on-disc tribometer attached with LVDT arrangement. Impact of three control factors, load (N), sliding distance (m) and wt. % of SiC (%) on the performance characteristics such as wear rate, frictional force and specific wear rate in unlubricated dry sliding conditions is inspected to obtain the optimum level of the process parameters. Analysis of variance (ANOVA) test was performed to analyze the impact of three control factors on wear rate, frictional force and specific wear rate. Experimental analysis revealed that the wear behavior is enhanced under optimum experimental states. Optical microscopic examinations of the worn out samples is also conducted to describe the wear mechanism of the matrix composites.

Wear conduct of aluminum matrix composites: A parametric strategy using Taguchi based GRA integrated with weight method

Abstract The present work concentrates on the preparation of AA6063-SiC metal matrix composites and analysis of wear properties using the hybrid Taguchi-GRA-Weight method. AA6063 al-alloy matrix composites were prepared by liquid metallurgy stir casting process by varying the weight fraction of SiC particles in steps of 3.5 weight percentage. The SiC particles of average particle size 37 μm were varied in three steps viz, 3.5, 7, and 10.5%. The experiments were performed in accordance with the L27 Taguchi orthogonal array to get the wear data in a controlled manner. Effect of three process parameters, Load (N), Sliding distance (m) and wt. % of SiC on the quality characteristics wear and frictional force in non lubricated dry slippery states was analyzed by using pin-on-disc wear and friction monitor. The optimum level of process parameters was obtained by using GRA for multiple quality characteristics. ANOVA was used to analyze the effect of individual process parameters on wear and frictional force. The experimental outcomes confirmed that the wear behavior of the prepared composites enhanced under optimal trial states. The wear examination results detailed that lower load of 20 N and moderate weight percentage (7 wt. % SiC) and sliding distance (1,046 m) produced minimum wear in the fabricated matrix composites. The optical microscopic analysis of the worn out specimens was also carried out to describe the wear mechanism. The validation of the predicted values done through confirmation experiment at optimal variable setting has shown a good agreement with the worn surface morphology.