Advertisement

On Performance Evaluation of Helical Grooved Tool During Rotary Tool Micro-ultrasonic Machining

  • Sandeep KumarEmail author
  • Akshay Dvivedi
Conference paper
Part of the Lecture Notes on Multidisciplinary Industrial Engineering book series (LNMUINEN)

Abstract

The present investigation reports on reduction of width overcut (WOC) and edge chipping in micro-channels developed by rotary tool micro-ultrasonic machining using helical grooved tool. The experiments were conducted to evaluate the effectiveness of the helical grooved tool in terms of WOC and edge chipping. The tool rotation speed, work feed rate, power rating and abrasive size were selected as variable parameters. The results showed that the tool with helical grooved tool assisted the abrasives to replenish from machining zone, thereby reducing the WOC and edge chipping. Both very low and very high tool rotation speed, work feed rate, abrasive mesh size and low power rating resulted in lower WOC and edge chipping. The parametric combination of tool rotation speed 300 rpm, workpiece feed rate 20 mm/min, power rating 40% and abrasive mesh size #1200 resulted in lowest WOC and edge chipping and hence better form accuracy.

Keywords

Micro-USM Tool rotation Micro-channel WOC Edge chipping 

References

  1. 1.
    Yao, P., Garrett, J.S., Prather, D.W.: Three-dimensional lithographical fabrication ofmicrochannels. J. Micro-Electro-Mech. Syst. 14, 799–805 (2005)Google Scholar
  2. 2.
    Jáuregui, A.L., Siller, H.R., Rodríguez, C.A., Elías-Zúñiga, A.: Evaluation of micromechanical manufacturing processes for microfluidic devices. Int. J. Adv. Manuf. Technol. 48, 963–972 (2010)CrossRefGoogle Scholar
  3. 3.
    Liu, X., DeVor, R.V., Kapoor, S.G., Ehmann, K.F.: The mechanics of machining at the micro-scale: assessment of the current state of the science. J. Manuf. Sci. Eng. 126, 666–678 (2004)CrossRefGoogle Scholar
  4. 4.
    Pandey, P.C., Shan, H.S.: Modern Machining Processes, pp. 7–38. Tata McGraw-Hill Education Pvt. Ltd. (1980)Google Scholar
  5. 5.
    Thoe, T.B., Aspinwall, D.K., Wise, M.L.H.: Review on ultrasonic machining. Int. J. Mach. Tools Manuf. 38(4), 239–255 (1998)CrossRefGoogle Scholar
  6. 6.
    Shaw, M.C.: Ultrasonic grinding. Microtechnic 10(6), 257–265 (1956)Google Scholar
  7. 7.
    Cook, N.H.: Manufacturing Analysis, pp. 133–138. Addison-Wesley, New York (1996)Google Scholar
  8. 8.
    Miller, G.E.: Special theory of ultrasonic machining. J. Appl. Phys. 28(2), 149–156 (1957)CrossRefGoogle Scholar
  9. 9.
    Pei, W., Yu, Z., Li, J., Ma, C., Xu, W., Wang, X., Natsu, W.: Influence of abrasive particle movement in micro USM. Procedia CIRP 6, 551–555 (2013)CrossRefGoogle Scholar
  10. 10.
    Jain, V., Sharma, A.K., Kumar, P.: Fabrication of microchannels using layer-by-layer machining in micro USM. In: Proceedings of the All India Manufacturing Technology Design and Research Conference, Jadhavpur, India (2012)Google Scholar
  11. 11.
    Cheema, M.S., Dvivedi, A., Sharma, A.K., Acharya, S.: Experimental investigations in development of 3D microchannels through ultrasonic micromachining. In: Proceedings of the 9th International Workshop on Microfactories, Honolulu, USA, pp. 92–95 (2014)Google Scholar
  12. 12.
    Kumar, S., Dvivedi, A.: Investigations on fabrication of microchannels using rotary tool micro-ultrasonic machining. In: Proceedings of the All India Manufacturing Technology Design and Research Conference, Pune, India, pp. 444–447 (2016)Google Scholar
  13. 13.
    Kumar, S., Dvivedi, A.: Experimental investigation on drilling of borosilicate glass using micro-USM with and without tool rotation: a comparative study. Int. J. Addit. Subtract. Mater. Manuf. 1(3–4), 213–222 (2017)Google Scholar
  14. 14.
    Kumar, S., Dvivedi, A.: Fabrication of microchannels using rotary tool micro-USM: an experimental investigation on tool wear reduction and form accuracy improvement. J. Manuf. Process. 32, 802–815 (2017)Google Scholar
  15. 15.
    Chemical composition of borosilicate glass. 05 May 2018. http://www.udel.edu/chem/GlassShop/PhysicalProperties.htm
  16. 16.
    Properties of borosilicate glass. 05 May 2018. http://www.technosklo.com/userdata/properties-of-manufactured-glasses

Copyright information

© Springer Nature Singapore Pte Ltd. 2020

Authors and Affiliations

  1. 1.Department of Mechanical and Industrial EngineeringIndian Institute of Technology RoorkeeRoorkeeIndia

Personalised recommendations