MODELING OF THE MECHANISM OF MATERIAL REMOVAL IN ULTRASONIC DRILLING USING FINITE ELEMENT METHOD

Abstract

Advanced engineering ceramics plays an increasingly important role in the modern manufacturing industries, especially in aerospace, automotive, electronics, and cutting tool industries because of its superior properties such as chemical inertness, high strength and high stiffness at elevated temperatures, high strength to weight ratio, high hardness, corrosion resistance, and oxidation resistance. USM has a great potential for applications in precision machining of ceramics, however, the material removal mechanism especially with respect to the microstructure and properties of the work material is not well understood. The stresses developed in the subsurface are of critical importance when machining brittle ceramics as the inherent microstructural variations and subsurface flaw characteristics influence the resultant stress distributions in the subsurface. It is necessary to investigate and understand the micro-material removal mechanism in ultrasonic mechanism for improving its efficiency and precision in machining of ceramics. In this work, the study of mechanism of material removal in brittle material with emphasis on ceramics with no subsurface defects is carried out using Finite element method. The ANSYS software has been employed to model the problem and the same is used to evaluate the stresses. An attempt is made to correlate the stress pattern with the failure mechanism in the brittle materials. An attempt has been made to find the material removal rate from the FEM model. Further an experiment is carried out using Taguchi experimental design to investigate the effect of Static Load, Amplitude, and Concentration of Abrasives, on the material removal rate and find which parameter is mostly affecting the material removal rate.