Parametric optimization of ultrasonic machining of co-based super alloy using the Taguchi multi-objective approach

Stellite 6 is the most generally useful cobalt alloy, having excellent resistance to many forms of mechanical and chemical degradation over a wide temperature range. Therefore, in particular, their use in aerospace projects world wide has provided confidence leading to acceptance as prime material for aerospace vehicles in recent years. This paper outlines the effectiveness of the ultrasonic machining of stellite 6 in terms of tool wear rate of the tool used and the material removal rate of work piece produced. The optimum combination of various input factors as type of abrasive slurry, their size and concentration, nature of tool material and power rating of the machine for the ductile chip formation in the machining of stellite 6 has been determined by applying the Taguchi multi-objective optimization technique and F-test. The analysis of results has been done using the statistica 7.0 software and results obtained are validated by conducting the confirmation experiments. The study shows the considerable improvement in multiple S/N ratio as compared to initial cutting conditions.

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