Fabricating tool for ultrasonic machining using reverse engineering

ABSTRACT Developing tools for ultrasonic machining processes is one of the most challenging tasks, because the shape of the machined surface of the workpiece is a replica of the tool surface. In this research, using reverse engineering (RE), the tool has been designed and fabricated for the ultrasonic machining (USM) process. Zirconia is a very hard and brittle bio-ceramic material and is highly biocompatible. Nowadays, zirconia material is used for producing the acetabular cup for hip joint. In this research work, an attempt has been made to apply the RE for developing the CAD model of a USM tool from the existing hemispherical shape cavity on a zirconia workpiece. Experimental analysis has been undertaken for generating the hemispherical shape cavity on zirconia bio-ceramics with the help of these developed tools. Through a number of graphical plots, comparisons of diametrical deviation and circularity error have been made using RE and without RE. Comparisons have also been made for justifying the accuracy of the tool development by RE with respect to the initial existing hemispherical shape cavity and developed tool for USM.

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