Abstract
Titanium is known as the metal of the future because of its excellent combination of properties such as high strength-to-weight ratio, low thermal conductivity, and high corrosion resistance. Machining of titanium, however, is considered as cumbersome with the conventional manufacturing practices, and there is a critical need of developing and establishing cost-effective methods of machining. This investigation is focused on exploring the use of ultrasonic machining, a nontraditional machining process for commercial machining of pure titanium (American Society for Testing and Materials grade-I) and evaluation of material removal rate under controlled experimental conditions. The optimal settings of parameters are determined through experiments planned, conducted, and analyzed using Taguchi method. An attempt has been made to construct a micro-model for prediction of material removal rate in ultrasonic machining of titanium using dimensional analysis. The predictions from this model have been validated by conducting experiments. The microstructure of the machined surface under different experimental conditions has been studied using scanning electron microscopy. A relation was established between the mode of material removal and the energy input rate corresponding to the different process conditions.
Similar content being viewed by others
References
ASM Int (1988) Titanium: a technical guide. ASM Int, Materials Park, pp 75–85
Bagchi TP (1993) Taguchi methods explained: practical steps to robust design. Prentice Hall of India Private Ltd, 0-87692-80804 pp 11–19.
Barash MM, Watanapongse D (1970) On the effect of ambient pressure on the rate of material removal in ultrasonic machining. Int J Mech Sci 12:775–779
Benedict GF (1987) Non traditional manufacturing processes. Marcel Dekker, Inc., New York, pp 67–86
Churi NJ, Wang ZM, Jeong W (2006) Rotary ultrasonic machining of titanium alloy: effects of machining variables. Mach Sci Technol 10:301–321
Ezugwu EO, Wang ZM (1997) Titanium alloys and their machinability—a review. J Mater Process Technol 68(1–4):262–274
Goetze D (1956) Effect of vibration amplitude, frequency, and composition of the abrasive slurry on the rate of ultrasonic machining in Ketos Tool Steel. J Acoust Soc Am 28(6):1033–1045
Guzzo PL, Shinohara AH (2004) A comparative study on ultrasonic machining of hard and brittle materials. J Braz Soc Mech Sci Eng 26(1):56–64
Hicks R, Turner VK (1999) Fundamental concepts in the design of experiments, 5th edn. Oxford University Press, New York, pp 134–139
Hong SY, Markus I, Jeong W (2001) New cooling approach and tool life improvement in cryogenic machining of titanium alloy Ti-6Al-4V. Int J Mach Tools Manuf 41:2245–2260
Hu P, Zhang ZM, Pei ZJ (2002) Modeling of material removal rate in rotary ultrasonic machining: designed experiments. J Mater Process Technol 129(1):339–344
Kazantsev VF (1966) Improving the output and accuracy of ultrasonic machining. Mach Tool 37(4):33–39
Kennedy DC, Grieve RJ (1975) Ultrasonic machining—a review. Prod Eng 54(9):481–486
Komaraiah M, Reddy PN (1993) A study on the influence of work piece properties in ultrasonic machining. Int J Mach Tools Manuf 33:495–505
Komaraiah M, Reddy PN (1993) Relative performance of tool materials in ultrasonic machining. Wear 161(1–2):1–10
Kremer D (1991) New developments in ultrasonic machining. SME Technical Paper, MR91-522, p 13
Kumar J, Khamba JS, Mohapatra SK (2008) An investigation into the machining characteristics of titanium using ultrasonic machining. Int J Mach Machine Mater 3(1–2):143–161
Markov AI (1959) Kinematics of the dimensional ultrasonic machining method. Mach Tool 30(10):28–31
Neppiras EA (1957) Ultrasonic machining-II. Operating conditions and performance of ultrasonic drills. Philips Tech Rev 18(12):368–379
Pandey PC, Shan HS (1980) Modern machining processes. Tata McGraw-Hill Publications, New Delhi, pp 7–38
Pentland EW, Ektermanis JA (1965) Improving ultrasonic machining rates—some feasibility studies. Trans ASME J Eng Ind 87:39–46
Ross PJ (1988) Taguchi technique for quality engineering. McGraw-Hill Book Company, New York, pp 45–48
Singh R, Khamba JS (2006) Ultrasonic machining of titanium and its alloys—a review. J Mater Process Technol 173(2):125–135
Singh R, Khamba JS (2007) Investigation for ultrasonic machining of titanium and its alloys. J Mater Process Technol 183(2–3):363–367
Singh R, Khamba JS (2007) Taguchi technique for modeling material removal rate in ultrasonic machining of titanium. Mater Sci Eng 460–461:365–369
Smith TJ (1973) Parameter influences in ultrasonic machining. Tribol Int 11(5):196–198
Thoe TB, Aspinwall DK, Wise MLH (1998) Review on ultrasonic machining. Int J Mach Tools Manuf 38(4):239–255
Velasquez JD, Bolle B, Chevrier P, Tidu A (2007) Metallurgical study on chips obtained by high speed machining of Ti-6Al-4V alloy. Mater Sci Eng 452–453:469–475
Wiercigroch M, Neilson RD, Player MA (1999) Material removal rate prediction for ultrasonic drilling of hard materials using an impact oscillator approach. Phys Lett 259(2):91–96
Wood RA, Favor RJ (1972) Titanium alloys handbook. Air Force Materials Laboratory, Ohio, 45433, pp 45–46
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Kumar, J., Khamba, J.S. Modeling the material removal rate in ultrasonic machining of titanium using dimensional analysis. Int J Adv Manuf Technol 48, 103–119 (2010). https://doi.org/10.1007/s00170-009-2287-1
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-009-2287-1