Abstract: Ultrasonic machining is one of the most widely used non-traditional machining processes for machining of materials that are relatively brittle, hard, and fragile such as advanced ceramics, refractories, crystals, quartz etc. Present article has been targeted at investigating the impact of different experimental conditions (power rating, cobalt content, tool material, thickness of work piece, tool geometry, and abrasive grit size) on over cut in ultrasonic drilling of WC-Co composite material. Taguchi’s L-36 orthogonal array has been employed for conducting the experiments. Significant factors have been identified using analysis of variance (ANOVA) test. The experimental results revealed that abrasive grit size and tool material are most significant factors for over cut.
Abstract: The present study deals with the modeling and simulation of flow through an annular reactor at different hydrodynamic conditions using computational fluid dynamics (CFD) to investigate the flow behavior. CFD modeling was utilized to predict velocity distribution and average velocity in the annular geometry. The results of CFD simulations were compared with the mathematically derived equations and already developed correlations for validation purposes. CFD modeling was found suitable for predicting the flow characteristics in annular geometry under laminar flow conditions. It was observed that CFD also provides local values of the parameters of interest in addition to the average values for the simulated geometry.
Abstract: Ultrasonic machining (USM) is a non-traditional
machining process being widely used for commercial machining of
brittle and fragile materials such as glass, ceramics and
semiconductor materials. However, USM could be a viable
alternative for machining a tough material such as titanium; and this
aspect needs to be explored through experimental research. This
investigation is focused on exploring the use of ultrasonic machining
for commercial machining of pure titanium (ASTM Grade-I) and
evaluation of tool wear rate (TWR) under controlled experimental
conditions. The optimal settings of parameters are determined
through experiments planned, conducted and analyzed using Taguchi
method. In all, the paper focuses on parametric optimization of
ultrasonic machining of pure titanium metal with TWR as response,
and validation of the optimized value of TWR by conducting
confirmatory experiments.
Abstract: The use of hard and brittle material has become
increasingly more extensive in recent years. Therefore processing of
these materials for the parts fabrication has become a challenging
problem. However, it is time-consuming to machine the hard brittle
materials with the traditional metal-cutting technique that uses
abrasive wheels. In addition, the tool would suffer excessive wear as
well. However, if ultrasonic energy is applied to the machining
process and coupled with the use of hard abrasive grits, hard and
brittle materials can be effectively machined. Ultrasonic machining
process is mostly used for the brittle materials. The present research
work has developed models using finite element approach to predict
the mechanical stresses sand strains produced in the tool during
ultrasonic machining process. Also the flow behavior of abrasive
slurry coming out of the nozzle has been studied for simulation using
ANSYS CFX module. The different abrasives of different grit sizes
have been used for the experimentation work.