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Investigations into the surface quality and micro-hardness in the ultrasonic machining of titanium (ASTM GRADE-1)

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Abstract

In the current study, the influence of various process parameters such as tool material, abrasive type, slurry grit size and power rating on the surface quality and the micro-hardness of the machined surface has been reported while machining pure titanium (ASTM Grade-I) using ultrasonic machining. Taguchi’s robust design approach has been utilized for planning the experiments and optimizing the experimental results of surface roughness and micro-hardness. The surface topography of the machined samples revealed that the mode of material removal is related to the energy input rate. The mode of material removal may change from plastic deformation to brittle fracture under varied conditions of energy input rate. The hardness gradient has also been evaluated for selected process conditions and correlated with the energy input rate corresponding to each of the conditions.

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Abbreviations

MRR:

Material removal rate

TWR:

Tool wear rate

SR:

Surface roughness

S/N :

Signal-to-noise ratio

DOE:

Design of experiments

OA:

Orthogonal array

SS:

Sum of squares

MS:

Mean square

DOF:

Degrees of freedom

F :

Fisher’s ratio

P :

Probability value

TQNL:

Total normalized quality loss

MSNR:

Multiple S/N ratio

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Acknowledgments

The author would like to thank Mr. K. Ramesh (GM, MIDHANI, Hyderabad, India) and Mr. S.S. Arora (Punjab Abrasives, Mohalli, India) for providing necessary materials for the research work. The author is also thankful to Mr. Trilok Singh and Mr. Sukhdev Chand (Lab Superintendents, TU, Patiala) for providing laboratory facilities. The author feels indebted to Mr. Charlie Wilhite (Sonic-Mill, USA) for providing the accessories for USM apparatus and for giving invaluable guidance from time to time.

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  1. Department of Mechanical Engineering, National Institute of Technology, Kurukshetra, India

    Jatinder Kumar

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Correspondence to Jatinder Kumar.

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Technical Editor: Alexandre Mendes Abrao.

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Kumar, J. Investigations into the surface quality and micro-hardness in the ultrasonic machining of titanium (ASTM GRADE-1). J Braz. Soc. Mech. Sci. Eng. 36, 807–823 (2014). https://doi.org/10.1007/s40430-014-0130-6

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  • DOI: https://doi.org/10.1007/s40430-014-0130-6

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