Skip to main content
SpringerLink
Log in

Chipping minimization in drilling ceramic materials with rotary ultrasonic machining

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Ultrasonic machining (USM) has been considered as a new cutting technology that does not rely on the conductance of the workpiece. USM presents no heating or electrochemical effects, with low surface damage and small residual stresses on workpiece material, such as glass, ceramics, and others; therefore, it is used to drill microholes in brittle materials. However, this process is very slow and tool wear dependent, so the entire process has low efficiency. Therefore, to increase microhole drilling productivity or hole quality, rotary ultrasonic machining (RUM) is considered as a strong alternative to USM. RUM, which presents ultrasonic axial vibration with tool rotation, is an effective solution for improving cutting speed, precision, tool wear, and other machining responses beyond those of the USM. This study aims to reduce the microchipping or cracking at the exit of the hole, which inevitably occurs when brittle materials are drilled, with consideration of tool wear. To this end, response surface analysis and desirability functions are used for experimental optimization. The experimental results showed that the proposed RUM scheme is suitable for microhole drilling.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Singh R, Khamba JS (2006) Ultrasonic machining of titanium and its alloys: a review. J Mater Process Technol 173:125–135

    Article  Google Scholar 

  2. Jahanmir S, Ives LK, Ruff AW, Peterson MB (1992) Ceramic machining: assessment of current practice and research needs in the United States, NIST Special Publication 834

  3. Singh R, Khamba JS (2007) Macromodel for ultrasonic machining of titanium and its alloys: designed experiments. J Eng Manuf 221(2):221–229, 9

    Article  Google Scholar 

  4. Li ZC, Cai L, Pei ZJ, Treadwell C (2006) Edge-chipping reduction in rotary ultrasonic machining of ceramics: finite element analysis and experimental verification. Int J Mach Tools Manuf 46:1469–1477

    Article  Google Scholar 

  5. Zeng WM, Li ZC, Pei ZJ, Treadwell C (2005) Experimental observation of tool wear in rotary ultrasonic machining of advanced ceramics. Int J Mach Tools Manuf 45:1468–1473

    Article  Google Scholar 

  6. Legge P (1964) Ultrasonic drilling of ceramics. Ind Diam Rev 24(278):20–24

    Google Scholar 

  7. Legge P (1966) Machining without abrasive slurry. Ultrasonic 4(3):157–162

    Article  Google Scholar 

  8. Pei ZJ, Ferreira PM (1998) Modeling of ductile-mode material removal in rotary ultrasonic machining. Int J Mach Tools Manuf 38:1399–1418

    Article  Google Scholar 

  9. Li ZC, Jiao Y, Deines TW, Pei ZJ, Treadwell C (2005) Rotary ultrasonic machining of ceramic matrix composites: feasibility study and designed experiments. Int J Mach Tools Manuf 45:1402–1411

    Article  Google Scholar 

  10. Liu J, Zhang D, Qin L, Yan L (2012) Feasibility study of the rotary ultrasonic elliptical machining of carbon fiber reinforced plastics (CFRP). Int J Mach Tools Manuf 53:141–150

    Article  Google Scholar 

  11. Liu D, Cong WL, Pei ZJ, Tang Y (2012) A cutting force model for rotary ultrasonic machining of brittle materials. Int J Mach Tools Manuf 52:77–84

    Article  Google Scholar 

  12. Hu P, Zhang JM, Pei ZJ, Treadwell C (2002) Modeling of material removal rate in rotary ultrasonic machining: designed experiments. J Mater Process Technol 129:339–344

    Article  Google Scholar 

  13. Ya G, Qin HW, Yang SC, Xu YW (2002) Analysis of the rotary ultrasonic machining. J Mater Process Technol 129:182–185

    Article  Google Scholar 

  14. Gong H, Fang FZ, Hu XT (2010) Kinematic view of tool life in rotary ultrasonic side milling of hard and brittle materials. Int J Mach Tools Manuf 50:303–307

    Article  Google Scholar 

  15. Wiercigroch M, Neilson RD, Player MA (1999) Material removal rate prediction for ultrasonic drilling of hard materials using an impact oscillator approach. Phys Lett A 259(2):91–96

    Article  Google Scholar 

  16. www.sonicmill.com (2012) Sonicmill Company

  17. Chun SH, Ko TJ (2011) Study on the response surface model of machining error in internal lathe boring. Int J Precis Eng Manuf 12:177–182

    Article  Google Scholar 

  18. Montgomery DC (2005) Design and analysis of experiments. Wiley, New York, pp 405–463

    Google Scholar 

  19. Fuller D, Scherer W (1998) The desirability function: underlying assumptions and application implications. University of Charlottesville, VA, 22903

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. School of Mechanical Engineering, Yeungnam University, 214-1, Dae-dong, Gyeongsan, Kyoungbuk, 712-749, South Korea

    Jun Wei Liu & Tae Jo Ko

  2. Institute of Mechanical Engineering Technology, Kyungpook National University, 1370, Sankyuk-dong, Puk-ku, Daegu, 702-701, South Korea

    Dae Kyun Baek

Authors
  1. Jun Wei Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Dae Kyun Baek
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Tae Jo Ko
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Tae Jo Ko.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Liu, J.W., Baek, D.K. & Ko, T.J. Chipping minimization in drilling ceramic materials with rotary ultrasonic machining. Int J Adv Manuf Technol 72, 1527–1535 (2014). https://doi.org/10.1007/s00170-014-5766-y

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-014-5766-y

Keywords

Search

Navigation