An investigation into the effect of work material properties, tool geometry and abrasive properties on performance indices of ultrasonic machining

In the present investigation, the effect of several parameters such as abrasive material, abrasive grit size and tool geometry on the machining performance of USM has been explored in conjunction with 18 different work-tool combinations. The investigation includes six different work materials possessing a wide range of properties such as toughness and hardness; three tool materials and three types of tool geometries. Taguchi's L18 orthogonal array was used in this study to plan the experiments statistically. The results obtained were analysed by using analysis of variance test (ANOVA) and the significant factors that contribute to variation in the machining performance have been identified. The surface topography of the machined surface for different work materials was also explored in relation with the mechanical properties of the work material. Hard and brittle materials tend to fail by rapid brittle fracture of the surface under machining whereas the materials with higher toughness and ductility undergo significant amount of plastic deformation and strain hardening prior to the fracture.