Skip to main content
SpringerLink
Log in

Parameter Optimization of Rotary Ultrasonic Machining on Quartz Glass Using Response Surface Methodology (RSM)

  • Original Paper
  • Published:
Silicon Aims and scope Submit manuscript

Abstract

In the current research, rotary ultrasonic machining was used to drill holes in quartz material. The effect of different RUM parameters namely tool feed rate, tool rotational speed and ultrasonic power on material removal rate and surface roughness has been studied experimentally. The response surface methodology with central composite design has been used to design the experiments. From the desirability approach, the optimum setting of the rotary ultrasonic machining parameters was found to be the tool rotational speed of 4968 rpm, feed rate of 0.55 mm/min, and ultrasonic power of 80% for achieving the maximum MRR of 0.2135 mm3/s and minimum SR of 0.3685 μm. Microstructure analysis of the machined surface was performed by using scanning electron microscopy in order to study the mechanisms of material removal under the different settings of RUM parameters. It was observed that at very low feed (0.08 mm/min) and high rpm (5681) the material is predominantly removed by plastic deformation whereas at high feed (0.92 mm/min) and low rpm (2318) the material is removed by brittle fracture.

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. Rattan N, Mulik RS (2018) Experimental set up to improve machining performance of silicon dioxide ( quartz ) in magnetic field assisted TW-ECSM process. Silicon:1–9. https://doi.org/10.1007/s12633-018-9818-z

    Article  CAS  Google Scholar 

  2. Ji L, Hu Y, Li J, Wang W, Jiang Y (2015) High-precision micro-through-hole array in quartz glass machined by infrared picosecond laser. Appl Phys A Mater Sci Process 121:1151–1157. https://doi.org/10.1007/s00339-015-9482-8

    Article  CAS  Google Scholar 

  3. Kuo KY, Wu KL, Yang CK, Yan BH (2015) Effect of adding SiC powder on surface quality of quartz glass microslit machined by WECDM. Int J Adv Manuf Technol 78:73–83. https://doi.org/10.1007/s00170-014-6602-0

    Article  Google Scholar 

  4. Dubey AK, Yadava V (2008) Laser beam machining — a review. Int J Mach Tools Manuf 48(48):609–628. https://doi.org/10.1016/j.ijmachtools.2007.10.017

    Article  Google Scholar 

  5. Jain VK, Adhikary S (2008) On the mechanism of material removal in electrochemical spark machining of quartz under different polarity conditions. J Mater Process Technol 200:460–470. https://doi.org/10.1016/j.jmatprotec.2007.08.071

    Article  CAS  Google Scholar 

  6. Jain VK, Chak SK (2000) Electrochemical spark trepanning of alumina and quartz. Mach Sci Technol 4:277–290. https://doi.org/10.1080/10940340008945710

    Article  CAS  Google Scholar 

  7. Kuo KY, Wu KL, Yang CK, Yan BH (2013) Wire electrochemical discharge machining (WECDM) of quartz glass with titrated electrolyte flow. Int J Mach Tools Manuf 72:50–57. https://doi.org/10.1016/j.ijmachtools.2013.06.003

    Article  Google Scholar 

  8. Guzzo PL, Raslan AA, De Mello JDB (2003) Ultrasonic abrasion of quartz crystals. Wear 255:67–77. https://doi.org/10.1016/S0043-1648(03)00094-2

    Article  CAS  Google Scholar 

  9. Antil P, Singh S, Manna A (2018) Electrochemical discharge drilling of SiC reinforced polymer matrix composite using Taguchi’s Grey relational analysis. Arab J Sci Eng 43:1257–1266. https://doi.org/10.1007/s13369-017-2822-6

    Article  CAS  Google Scholar 

  10. Rattan N, Mulik RS (2017) Experimental investigations and multi-response optimization of silicon dioxide (quartz) machining in magnetic field assisted TW-ECSM process. Silicon 9:663–673. https://doi.org/10.1007/s12633-016-9521-x

    Article  CAS  Google Scholar 

  11. Wang J, Feng P, Zhang J (2016) Improving hole exit quality in rotary ultrasonic machining of ceramic matrix composites using a compound step-taper drill. https://doi.org/10.1016/j.ceramint.2016.05.095

    Article  CAS  Google Scholar 

  12. 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. https://doi.org/10.1016/j.ijmachtools.2005.01.031

    Article  Google Scholar 

  13. Pei ZJ, Ferreira PM, Kapoor SG, Haselkorn M (1995) Rotary ultrasonic machining for face milling of ceramics. Int J Mach Tools Manuf 35:1033–1046. https://doi.org/10.1016/0890-6955(94)00100-X

    Article  Google Scholar 

  14. Kumar V, Singh H (2018) Rotary ultrasonic Drilling of Silica Glass BK-7: microstructural investigation and process optimization through TOPSIS. Silicon 1(15):471–485. https://doi.org/10.1007/s12633-018-9933-x

    Article  CAS  Google Scholar 

  15. Kumar J (2013) Ultrasonic machining-a comprehensive review, Ultrasonic Machining—A Comprehensive Review

  16. Pei ZJ, Prabhakar D, Ferreira PM (1995) A mechanistic approach to the prediction of material removal rates in rotary ultrasonic machining. Trans ASME 117:142–151

    Google Scholar 

  17. Z.J. Pei, P.M. Ferreira MH (1995) Plastic flow in rotary ultrasonic machining of ceramics. J Mater Process Technol 48:771–777

    Article  Google Scholar 

  18. Ya G, Qin HW, Yang SC, Xu YW (2002) Analysis of the rotary ultrasonic machining mechanism. J Mater Process Technol 129:182–185. https://doi.org/10.1016/S0924-0136(02)00638-6

    Article  Google Scholar 

  19. Pei ZJ, Ferreira PM (1998) Modeling of ductile-mode material removal in rotary ultrasonic machining. Int J Mach Tools Manuf 38:1399–1418. https://doi.org/10.1016/S0890-6955(98)00007-8

    Article  Google Scholar 

  20. Hu P, Zhang JM, Pei ZJ, Treadwell C l (2002) Modeling of material removal rate in rotary ultrasonic machining: designed experiments. J Mater Process Technol 129:339–344. https://doi.org/10.1016/S0924-0136(02)00686-6

    Article  CAS  Google Scholar 

  21. 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. https://doi.org/10.1016/j.ijmachtools.2005.01.034

    Article  Google Scholar 

  22. Feng P, Wang J, Zhang J, Zheng J (2017) Drilling induced tearing defects in rotary ultrasonic machining of C/SiC composites. Ceram Int 43:791–799. https://doi.org/10.1016/j.ceramint.2016.10.010

    Article  CAS  Google Scholar 

  23. Churi NJ, Pei ZJ, Treadwell C (2007) Rotary ultrasonic machining of titanium alloy ( Ti-6Al-4V ): effects of tool variables. 1:

  24. 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. https://doi.org/10.1016/j.ijmachtools.2009.12.006

    Article  Google Scholar 

  25. Wu Jiaqing, Cong Weilong, Williams Robert PZP (2011) Dynamic Process Modeling for Rotary Ultrasonic Machining of Alumina. 133:. https://doi.org/10.1115/1.4004688

  26. Zhang C, Feng P, Pei Z, Cong W (2014) Rotary ultrasonic machining of sapphire : feasibility study and designed experiments 590:523–528. https://doi.org/10.4028/www.scientific.net/KEM.589-590.523

    Article  Google Scholar 

  27. Cong WL, Pei ZJ, Deines TW, Liu DF, Treadwell C (2013) Rotary ultrasonic machining of CFRP / Ti stacks using variable feedrate. Compos Part B 52:303–310. https://doi.org/10.1016/j.compositesb.2013.04.022

    Article  Google Scholar 

  28. Zhang CL, Feng PF, Wu ZJ, Yu DW (2011) An experimental study on processing performance of rotary ultrasonic drilling of K9 glass. Adv Mater Res 230–232:221–225. https://doi.org/10.4028/www.scientific.net/AMR.230-232.221

    Article  Google Scholar 

  29. Feng Q, Cong WL, Pei ZJ, CZR (2012) Rotary ultrasonic machining of carbon Fiber-reinforced polymer : feasibility study. Mach Sci Technol 16(3):380–398. https://doi.org/10.1080/10910344.2012.698962

    Article  CAS  Google Scholar 

  30. Thirumalai Kumaran S, Ko TJ, Li C, Yu Z, Uthayakumar M (2017) Rotary ultrasonic machining of woven CFRP composite in a cryogenic environment. J Alloys Compd 698:984–993. https://doi.org/10.1016/j.jallcom.2016.12.275

    Article  CAS  Google Scholar 

  31. Wang J, Zha H, Feng P, Zhang J (2016) On the mechanism of edge chipping reduction in rotary ultrasonic. Precis Eng 8(12):231–235. https://doi.org/10.1016/j.precisioneng.2015.12.008

    Article  Google Scholar 

  32. Wang J, Wang J, Feng P, Zhang J (2016) Reduction of edge chipping in rotary ultrasonic machining by using step drill : a feasibility study. https://doi.org/10.1007/s00170-016-8655-8

    Article  Google Scholar 

  33. Sindhu D, Thakur L, Chandna P (2018) Multi-objective optimization of rotary ultrasonic machining parameters for quartz glass using Taguchi-Grey relational analysis (GRA). Silicon. https://doi.org/10.1007/s12633-018-0019-6

    Article  Google Scholar 

  34. Wang J, Feng P, Zhang J, Cai W, Shen H (2016) Investigations on the critical feed rate guaranteeing the effectiveness of rotary ultrasonic machining. Ultrasonics. 74:81–88. https://doi.org/10.1016/j.ultras.2016.10.003

    Article  PubMed  Google Scholar 

  35. Cong WL, Pei ZJ, Treadwell C (2015) Vibration Amplitude in Rotary Ultrasonic Machining : A Novel Measurement Method and Effects of Process Variables 133:1–5. https://doi.org/10.1115/1.4004133

  36. Komaraiah M, Narasimha Reddy P (1991) Rotary ultrasonic machining— a new cutting process and its performance. Int J Prod Res 29:2177–2187. https://doi.org/10.1080/00207549108948077

    Article  Google Scholar 

  37. 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. https://doi.org/10.1016/j.ijmachtools.2011.10.007

    Article  Google Scholar 

  38. Cong WL, Pei ZJ, Treadwell C (2014) Preliminary study on rotary ultrasonic machining of CFRP / Ti stacks. Ultrasonics 54:1594–1602. https://doi.org/10.1016/j.ultras.2014.03.012

    Article  CAS  PubMed  Google Scholar 

  39. Singh RP, Singhal S (2016) Experimental study on rotary ultrasonic machining of alumina ceramic : microstructure analysis and multi-response optimization. J Mater Des Apllications 0:1–20. https://doi.org/10.1177/1464420716657370

    Article  Google Scholar 

  40. Pei ZJ, Ferreira PM (1999) An experimental investigation of rotary ultrasonic face milling. Int J Mach Tools Manuf 39:1327–1344. https://doi.org/10.1016/S0890-6955(98)00093-5

    Article  Google Scholar 

  41. Singh RP, Singhal S (2017) Rotary ultrasonic machining of macor ceramic: an experimental investigation and microstructure analysis. Mater Manuf Process 32:927–939. https://doi.org/10.1080/10426914.2016.1198033

    Article  CAS  Google Scholar 

  42. Bifano TG, Dow T a, Scattergood RO (1991) Ductile-Regime Grinding: A New Technology for Machining Brittle Materials. J Eng Ind:113–184. https://doi.org/10.1115/1.2899676

    Article  Google Scholar 

Download references

Acknowledgements

The author would like to thank Director, Wadia Institute of Himalayan Geology, Dehradun, Uttarakhand (India) for providing the SEM facility for microstructure analysis.

Author information

Authors and Affiliations

  1. Mechanical Engineering Department, N.I.T. Kurukshetra, Haryana, 136119, India

    Dinesh Sindhu, Lalit Thakur & Pankaj Chandna

Authors
  1. Dinesh Sindhu
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Lalit Thakur
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Pankaj Chandna
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Dinesh Sindhu.

Additional information

Publisher’s Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Sindhu, D., Thakur, L. & Chandna, P. Parameter Optimization of Rotary Ultrasonic Machining on Quartz Glass Using Response Surface Methodology (RSM). Silicon 12, 629–643 (2020). https://doi.org/10.1007/s12633-019-00160-2

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12633-019-00160-2

Keywords

Search

Navigation