Micro rotary ultrasonic machining

Murali M. Sundaram, Aarati Sarwade, Krishna Rachuri, K. P. Rajurkar

Research output: Chapter in Book/Report/Conference proceedingConference contribution

3 Scopus citations

Abstract

Rotary ultrasonic machining (RUM) is a hybrid machining process capable of machining advanced engineering materials like ceramics, Ti-alloys, glass, quartz, structural ceramics, and silicon carbide at macro level. RUM employs the synergistic effect of material removal mechanisms of ultrasonic machining and diamond grinding. This paper explores the feasibility of downscaling RUM to achieve micromachining of brittle materials. Challenges encountered during the downscaling of RUM at a micro level, and methods used to resolve the same are explained. An in-house built test bed was used in this micro RUM feasibility study. Using micro electro discharge machining (micro EDM), the micro tools required for micro RUM were fabricated in-house, from a commercial macro tool made of polycrystalline diamond (PCD). Several process parameters influencing micro RUM have been identified. Experiments reveal that tool diameter, abrasive size, and static load are the major factors influencing the material removal rate. Except pitting, no other form of tool wear was observed in this feasibility study of micro RUM using PCD tool.

Original languageEnglish (US)
Title of host publicationTransactions of the North American Manufacturing Research Institution of SME - 37th Annual North American Manufacturing Research Conference, NAMRC 37
Pages621-628
Number of pages8
StatePublished - Nov 23 2009
Event37th Annual North American Manufacturing Research Conference, NAMRC 37 - Greenville, SC, United States
Duration: May 19 2009May 22 2009

Publication series

NameTransactions of the North American Manufacturing Research Institution of SME
Volume37
ISSN (Print)1047-3025

Conference

Conference37th Annual North American Manufacturing Research Conference, NAMRC 37
CountryUnited States
CityGreenville, SC
Period5/19/095/22/09

Keywords

  • Micro EDM
  • Micro RUM
  • Micromachining
  • PCD tool

ASJC Scopus subject areas

  • Mechanical Engineering
  • Industrial and Manufacturing Engineering

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  • Cite this

    Sundaram, M. M., Sarwade, A., Rachuri, K., & Rajurkar, K. P. (2009). Micro rotary ultrasonic machining. In Transactions of the North American Manufacturing Research Institution of SME - 37th Annual North American Manufacturing Research Conference, NAMRC 37 (pp. 621-628). (Transactions of the North American Manufacturing Research Institution of SME; Vol. 37).