Rotary Ultrasonic Machining of Ni based Alloys

IJIRST –International Journal for Innovative Research in Science & Technology| Volume 3 | Issue 12 | May 2017 ISSN (online): 2349-6010 Rotary Ultrasonic Machining of Ni based Alloys Dipesh Popli Department of Mechanical Engineering National Institute of Technology, Kurukshetra (Haryana), India Meenu Gupta Department of Mechanical Engineering National Institute of Technology, Kurukshetra (Haryana), India Abstract Inconel 718 is a high nickel content super alloy possessing high strength at elevated temperatures and resistance to oxidation and corrosion. The non-traditional manufacturing process of Rotary ultrasonic machining (RUM) possesses many advantages over traditional machining during the manufacture of Inconel 718 parts. An experimental investigation was conducted to determine the main RUM parameters which contribute to effects the metal removal rate and surface roughness of Inconel 718. It was found that feed rate is the most critical parameter in RUM. Keywords: RSM, Machining, Roughness, MR, Nickel _______________________________________________________________________________________________________ I. INTRODUCTION Super alloys maintain superior mechanical strength at elevated temperature. Super alloys contribute the largest group of materials in aerospace engineering. It reveals exceptional properties such as corrosion resistance, creep resistance, and retaining strength and hardness at high temperatures. Among super alloys, Ni- based alloys are most widely used in various manufacturing processes. Nickel Alloys and Their Properties Nickel alloys are valuable in many industries for their resistance to corrosion and their retention of strength as well as other mechanical properties in extreme temperatures. Nickel alloys are extensively used for the manufacturing of aero-engine components because of its high specific strength. During prolonged exposure to elevated temperatures, many types of metal begin to crack, deform, corrode, fatigue, etc. Nickel alloys, however, or known for the retention of essential mechanical properties, such as impact strength, yield strength, and hardness at very high temperatures, creep resistance depending on the grade. At higher temperature, Nickel alloys get the precipitation strength through precipitation hardening (Sunulahpasic & Oruc, 2011). Besides, it has broad applications in nuclear industries due to its superior mechanical properties such as high toughness, resistance to oxidation and corrosion, high tensile and rupture stresses etc. Wrought Nickel Based Alloys Wrought nickel-based alloys were developed from the basic 80% nickel, 20% chromium alloy used for over 50 years in electrical resistance applications. By the addition of small amounts of titanium and aluminium, their oxidation resistance and creep rupture strength improved. Machining parameter and tool geometry are the important parameters that affect the machinability properties. A machinability model may be defined as a functional relationship between the input parameters. During machining, tools are subjected to different pressures, which develop stress and friction between the tool and work material. This results in the progressive material loss in the cutting tool. Tool wear is a change of shape of tool from its original position resulting from gradual loss of tool material. The consequences of tool wear are poor surface finish and declining the quality of the final product. Surface finish is a very important designing aspect of mechanical elements and also presented as a quality indicator of manufacturing processes, Puertas and Luis (2003). Any machining process does not allow achieving the theoretical surface roughness due to defects appearing on machined surfaces due to rapid tool wear and imbalances in the process. This requires to measure surface quality of manufactured parts with accuracy. Aslan et al. (2007) and Hascalik et al. (2007) quoted in their research an optimum selection of process condition is extremely important as this one determine the surface quality and tool wear phenomena of the manufactured parts. In RUM process an improper selection of cutting parameters may cause undesired surface roughness and high tooling cost. Tool materials should have following properties during any conventional machining of Inconel 718 alloy [1]:  High hot hardness to resist high stress involved.  Excellent thermal conductivity to minimize thermal gradient and thermal shock.  Excellent chemical inertness to depress the tendency to react with Titanium.  Toughness and fatigue resistance to withstand chip segmentation process.  High compressive, tensile and shear strength. All rights reserved by www.ijirst.org 140 Rotary Ultrasonic Machining of Ni based Alloys (IJIRST/ Volume 3 / Issue 12/ 023) Machining of Nickel based Super Alloys Ni-based super alloys are sophisticated structured materials that are responsible for its poor machinability. It constituting an austenitic matrix, like stainless steels, and work hardens quickly due to excessive heat generation during machining. However, the combined effects of poor thermal properties, high temperature, strength, the tendency to severe work hardening, and high tool work piece affinity make machining of Ni- based alloys are tough to machine materials, (Arunachalam, Mannan, & Spowage, 2004). Because of these properties, the material results in high-temperature stress, and a thick adhering layer at the tool-work interface during machining. Several studies on the machining of nickel base alloys had disclosed surface integrity and tool wear mechanisms (Jawaid, Koksal, & Sharif, 2000). Even though there are several studies on the machining of nickel base alloys by ceramics, carbide tools remained to be the important tool material in machining this kind of material owing to their high toughness and low cost. Due to the advance of the machine tool and control system, high-speed machining (HSM) technology is becoming matured in recent years. In HSM, a higher metal removal rate is not the only advantage. It features several other aspects such as lower cutting force, surface quality improvement, etc. The applications of HSM for aircraft parts are `recognized for a longer time. Machining die steels by HSM and successfully applying it to die and mould manufacturing is another appealing example of the application of HSM in the manufacturing industry. These alloys likewise have the propensity to weld with the tool materials at the high temperature generated during machining. The tendency built up edge during machining and the occurrence of hard abrasive carbides in their microstructure also deters machinability of such materials. (Thakur & Gangopadhyay, 2016; Zhou, Bushlya, Avdovic, & Sthl, 2012). These characteristics of the alloys cause a high temperature (more than 1000°C) and high stresses in the cutting zone resulting in accelerated flank wear, cratering and notching, depending on the tool material and cutting conditions used (Khidhir & Mohamed, 2010). The excellent material toughness results in difficulty in chip breaking during the process. Moreover, localization of shear in the chip produces an abrasive saw-toothed edge which can make swarf handling difficult. As a result, their broad applications have been hindered by the high cost of machining with existing technology (e.g. laser, WEDM, EBM). Hence, there is a crucial need for consistent and cost-effective machining processes for nickel-based super alloys. Ultrasonic Machining The ultrasonic machine comes into existence to machine hard and complex materials such as ceramic, glass, titanium and super alloys. Although the principle of ultrasonic machining was recognized in 1927, the first useful description of the USM technique was not given in industry literature until about 1940. Ultrasonic machining is a mechanical type non-traditional machining process. It is employed to machine hard and brittle materials (both electrically conductive and nonconductive material) having hardness usually greater than 40 HRC. The process was first developed in the 1950s and was originally used for finishing EDM surfaces. In ultrasonic machining, a tool of the desired shape vibrates at an ultrasonic frequency (19 to 25 kHz.) with an amplitude of 15-50 Microns over work piece. Generally, the tool is pressed down with a feed force F. Between the tool and work, machining zone is flooded with hard abrasive particles generally in the form of water based slurry. As the tool vibrates over the work piece, abrasive particles act as indenter and indent both work and tool material. Abrasive particles, as they indent, the work material would remove the material from both tool and work piece. In Ultrasonic machining material removal is due to crack initiation, propagation and brittle fracture of material. USM is used for machining hard and brittle materials, which are poor conductors of electricity and thus cannot be processed by Electrochemical machining (ECM) or Electro discharge machining (EDM). The tool in USM is made to vibrate with high frequency to the work surface in the midst of the flowing slurry. The main reason for using ultrasonic frequency is to provide better performance. Audible frequencies of required intensities would be heard as thunderous sound and would cause fatigue and even permanent damage to the auditory apparatus. Rotary Ultrasonic machine (RUM) One of cost-effective machining methods for advanced and newer material is rotary ultrasonic machining (RUM). It is a hybrid machining process that combines the material removal mechanisms of diamond grinding assistant with ultrasonic vibration (USM). RUM devices contain a uniquely designed spindle that is coupled to an ultrasonic transducer. The ultrasonic power supply converts conventional line voltage into 20 kHz of electrical energy. This output is fed to the piezoelectric transducer located in the spindle, and the transducer converts the electrical input into mechanical vibrations. By changing the setting of the output control of the power supply, the amplitude of the ultrasonic vibration can be adjusted. A variety of tool shapes can be used for rotary ultrasonic machining, and ceramic and technical glass machining applications typically use either a diamond-impregnated or electroplated tool. Diamond-impregnated tools are more durable, but electroplated tools are less expensive, so the selection depends on the particular application All rights reserved by www.ijirst.org 141 Rotary Ultrasonic Machining of Ni based Alloys (IJIRST/ Volume 3 / Issue 12/ 023) Fig. 1: Rotary Ultrasonic machine (RUM) Machinability Parameters of Inconel 718 Machining parameter and tool geometry are the important parameters that affect the machinability properties. A machinability model may be defined as a functional relationship between the input parameters such as tool rotation, feed, and ultrasonic power rating (at which tool vibrates) the output responses of machining process such as machining rate, surface roughness, tool wear, conicity and circularity etc. In order to develop a mathematical model to predict the best value, it is necessary to conduct the experiments involving the tool material and the work material. The response information is obtained from the experimental work, by keeping tool rotation, feed and ultrasonic power rating as the function of RUM process. Different abrasive sizes of diamonds impregnated core drill tools are used to machine nickel based alloy Inconel 718. The use of different tool shapes such as plain, lateral slotted, slotted to cut this kind of material is investigated. During machining, tools are subjected to different pressures, which develop stress and friction between the tool and work material. This results in the progressive material loss in the cutting tool. Tool wear is a change of shape of tool from its original position resulting from gradual loss of tool material. The consequences of tool wear are poor surface finish and declining the quality of the final product. Surface finish is a very important designing aspect of mechanical elements and also presented as a quality indicator of manufacturing processes. Any machining process does not allow achieving the theoretical surface roughness due to defects appearing on machined surfaces due to rapid tool wear and imbalances in the process. This requires to measure surface quality of manufactured parts with accuracy. Aslan et al. (2007) and Hascalik et al. (2007) quoted in their research an optimum selection of process condition is extremely important as this one determine the surface quality and tool wear phenomena of the manufactured parts. In RUM process an improper selection of cutting parameters may cause undesired surface roughness and high tooling cost. Minimization of wear is the predominant factor which improves the surface quality as well as productivity of the product, Benghersallah et al (2008). The design of experiments is a powerful tool for modeling and analysis of process variables over some specific variable which is an unknown function of these process variables. Response surface methodology has been widely utilized in engineering analysis and consists of plan of experiments with the objective of acquiring data in a controlled way, in order to obtain information about the behaviour of a given process. Hence, the design of experiments by Response surface methodology of cutting parameters is adopted to study the responses. Response surface methodology (RSM) is a collection of mathematical and statistical techniques which are useful for modelling and analyzing engineering problems and developing, improving, and optimizing processes. It also has important applications in the design, development, and formulation of new products, as well as in the improvement of existing product designs. RSM consists of the experimental strategy for exploring the space of the process or input factors, empirical statistical modelling to develop an appropriate approximating relationship between the yield and the process variables, and optimization methods for finding the levels or values of the process variables that produce desirable values of the response outputs. Response surface method designs also help in quantifying the relationships between one or more measured responses and the vital input factors. The first step of RSM is to define the limits of the experimental domain to be explored. These limits are made possible to obtain a clear response from the model, [2], [3]. In most RSM problems, the form of the relationship between the independent variables and the response is unknown; it is approximated. Thus, the first step in RSM is to find an appropriate approximation for the true functional relationship between response and the set of independent variables. Traditional experimental design methods are very complicated and difficult to use. Additionally, these methods require a large number of experiments when the number of process parameters increases, Rosa et al All rights reserved by www.ijirst.org 142 Rotary Ultrasonic Machining of Ni based Alloys (IJIRST/ Volume 3 / Issue 12/ 023) (2009). In order to minimize the number of tests required, Taguchi experimental design method, a powerful tool for designing high-quality system, was developed by Taguchi. This method uses a special design of orthogonal arrays to study the entire parameter space with a small number of experiments only. Taguchi recommends analyzing the mean response for each run in the inner array, and he also suggests analyzing variation using an appropriately chosen signal-to-noise ratio (S/N). These S/N ratios are derived from the quadratic loss function, and three of them are considered to be standard and widely applicable; Lower is the best: the medium is better; larger is better, Mohan et al (2007). Regardless of the category of the performance characteristics, the lower S/N ratio corresponds to a better performance. The statistical analysis of the data was performed by analysis of variance (ANOVA) to study the contribution of the factor and interactions and to explore the effects of each process on the observed value. II. HISTORY OF RUM Ultrasonic machining has attracted lots of attention and has found its way into the industry on a relatively wide scale. By 19531954, the first tool of the ultrasonic machine, mostly based on drilling and milling machines, had been developed. By about 6th decay, tools of various types and sizes for the ultrasonic machine for a variety of purposes had been seen and some models had begun to come into continuous production. The process does not release a heat-affected zone, chemical/electrical alterations, shallow and compressive residual stress generated on the workpiece surface. Due to that increase the high-cycle fatigue failure of the material generated. However, in USM, the abrasive slurry has to be fed to and recollect from the gap between the tool and the workpiece. As a result, the machining rate slows significantly and even stops as the penetration depth increases. The slurry can also wear the wall of the machined hole as it passes back toward the surface, which restrictions accuracy, particularly for small holes. Furthermore, the abrasive slurry "machines" the tool itself, which causes considerable tool wear and, in turn, makes it tough to hold close tolerances. Abdo et al. (2013) used Taguchi optimization methodology to optimize Rotary Ultrasonic Machining (RUM) parameters for face milling of zirconia ceramic. The influence of the RUM parameters such as vibration frequency, vibration amplitude, spindle speed, feed rate, and depth of cut on cutting force and material removal rate (MRR) is studied. A three-level orthogonal array is used to determine the signal-to-noise (S/N) ratios based on Taguchi’s design of experiments. Taguchi methodology gives a systematic, simple and efficient approach for the process study of RUM. The depth of cut and feed rate affect the MRR by 46.15% each. [4] compared two kinds of ultrasonic face machining with free abrasives, namely, Non-rotating Ultrasonic Machining with Free Abrasives (NRUSM) and Rotary Ultrasonic Machining with Free Abrasives (RUSM) and designed the experimentation for the red granite, which is a typical hard-to-machine natural material. Cong et al. (2014) carried out an experimental investigation with a view to assessing the influence of several process parameters on quality attributes in RUM of CFRP/Ti stacks. Tool rotation and ultrasonic power were varied whereas feed rate kept fixed at 0.05 mm/s. The reported material removal rate (3.56mm 3 /s) was higher as compared to conventional drilling methods. This improvement in MRR was caused due to the combined effect of involved mechanisms, i.e. ultrasonic machining and conventional grinding in RUM process. [5] conducted an experimental study of rotary ultrasonic machining of CFRP composites to assess cutting forces under the influence of two different coolants namely; cold air and cutting fluid. Results show that difference in CF for both coolants did not change as ultrasonic power increases (from 0% to 80%) whereas it decreased as spindle speed increased. Churi et al. (2006) investigated cutting forces during RUM of titanium alloy and reported that the influence of spindle speed on CF produced through the process also depends on the workpiece type. The feed rate and ultrasonic power have significant effects on cutting force, material. Cutting force increases significantly as the feed rate increases and it decreases initially then increases as the ultrasonic power increases. (Zhang et al., 2014a) Experimental study on optical K9 glass shows the feed rate as the most influential factors that affect edge chipping size as compared to other parameters such as; ultrasonic power and spindle speed. (Churi et al., 2009) deal with the influence of feed rate and spindle speed in RUM of macor dental ceramics and concluded that the lower feed rate and higher spindle rotation could result into the lower value of chipping size. (Liu et al., 2013) A slight decrease in chipping size was reported as ultrasonic power ranges from 20% to 40%, whereas for further increase in ultrasonic power 40% to 50% chipping size increased significantly. Edge breakout phenomenon also depends upon the cutting forces generated in X and Y axis. Zhang et al. (2011b) deal with the influence of feed rate and spindle speed in RUM of K9 glass and concluded that the lower feed rate and higher spindle rotation could result in the lower value of chipping size. However, it was also stated that the effect of lower feed rate on the size of chipping was stronger than higher spindle speed. Liu et al. (2014) optimized the parametric setting for chipping minimization while performing RUM of alumina ceramic and optimized setting value of exit crack was 25.378 μm. W.L. Cong, Pei, & Treadwell, (2014) investigated the wear mechanism of diamond core drill in rotary ultrasonic elliptical machining of CFRP and results were also compared with conventional drilling (CD). More micro-fracture of diamond grains generated in RUEM resulted in smaller drilling force than that in CD. Study for RUM of CFRP composites revealed that the All rights reserved by www.ijirst.org 143 Rotary Ultrasonic Machining of Ni based Alloys (IJIRST/ Volume 3 / Issue 12/ 023) RUM tool of 7mm tuning length has the capability to drill 1400 holes and also has a longer life than that for twist drilling tools (Cong et al., 2012d). W. Zeng et al. (2005) performed an experimental investigation to illustrate the tool wear mechanisms in rotary ultrasonic machining of silicon carbide (SiC). Attritious wear and bond fracture were reported in RUM of silicon carbide, but the presence of grain fracture was not observed. Tool wear at the end face was found sterner than that on lateral face. Surface roughness (SR) of machined samples also gets affected by selecting the ranges of input variables in RUM. Several investigations in RUM have been carried out to recognize the SR under the influence of different process parameters. Debnath et al., (2014) reported increased value of SR with power rating while performing rotary- mode ultrasonic drilling of glass/epoxy composite laminates. Cong et al., (2012) conducted an experimental investigation on RUM of stainless steel with a view to assess the influence of process variables and their interactions on surface roughness. Cong et al., (2011) conducted the experiments by taking cold air as coolant in RUM process of CFRP composites. The surface roughness was observed to increase as ultrasonic power increased and decrease as spindle speed increased. There were no significant effects found for both coolants (cold air and cutting fluid). (Pei and Ferreira, 1999) and this can also be understood with the fact that more is the percentage of ductile mode material removal, the finer will be the machined surface. Cong et al. (2009) conducted an experimental investigation on RUM of stainless steel with a view to assess the influence of process variables and their interactions on surface roughness. Zhang et al. (2014a) conducted an experimental study to check out the influence of the controlled process variables in RUM of optical K9 glass using the compressed air as a coolant. Results revealed that SR increases as the ultrasonic power and feed rate increases, whereas it decreases as spindle speed increases. Kuruc et al. (2015) investigated experimentally the machined part roughness in rotary ultrasonic milling of poly-crystalline cubic boron nitride and validated the methods potential to machine such a hard material as lower roughness value was achieved. High level of spindle speed and larger grains of diamond abrasives resulted in lesser SR. (Ding et al., 2014) With a maximum percentage reduction of 23%, RUM of C/SiC composite confirms the process capability to produce holes with lower roughness as compared to traditional methods under similar operating condition This lower surface roughness reported with RUM process is associated with the fact, that the material removal was in the form of „micro sized chips‟ produced with ultrasonic assisted grinding action as compared to the conventional processes (such as; twist drilling, grinding process etc.) where larger sized craters/pits are formed over the machined hole resulting into higher surface roughness. (Liu et al., 2013), revealed the reduced cutting force and torque are responsible for better surface finish of drilled hole. Study on rotary ultrasonic grinding of ceramic material illustrates the influence of bond strength on the roughness of ground surface. It was revealed from the results that ceramic bonded tool resulted in the lower value of SR than that produced with iron and bronze bonded tools. (Bertsche et al., 2013) Fiber orientation also plays a vital role to signify SR in SiC matrix composites. Matrix form provides lower SR than that for 90 o and 0 o fiber orientation respectively. (Lv et al., 2013e) concluded the surface roughness was found to be lower taking feed rate of 200 mm/min and spindle speed at 12000 rpm while rotary ultrasonic machining of optical glass BK7 Singh & Singhal (2016) investigated the study of influence of several process parameters viz. RPM, feed rate, ultrasonic power, coolant pressure on surface roughness and chipping thickness in RUM of alumina ceramic. The microstructure analysis of the machined surface has also been studied to understand the mode of deformation that caused the removal of material from the work surface. The multi-objective optimization has also been undertaken using the desirability method through RSM. The results shows that with a parametric combination having lower feed rate and higher tool rotation offers more favorable conditions for the plastic mode deformation to occur in RUM of alumina ceramic as for this setting the penetration depth of diamond abrasives decreases considerably. In RUM of alumina ceramic, crack propagation often observed since the work surface under processing is getting stressed cyclically [6]–[11]. Temperature Cong et al. (2012b) Projected an experimental study on cutting temperature in RUM of CFRP composites by utilizing two methods for temperature measurement namely; fiber optic sensor based and thermocouple based. The experimental determination and comparison between input parameters and cutting temperature was also carried out. The results found that that as feed rate and ultrasonic power decreased, the maximum cutting temperature also falls down. Coolant The different types of coolant has been used by various researcher Cong et al. (2011b) conducted experimental study on RUM of CFRP composites. Results revealed that the torque generated during the experiments was higher with cold air than that with cutting fluid and decreased as tool rotation speed was raised from 1000 rpm to 5000 rpm. Zhang et al. (2014a) conducted an experimental study to check out the influence of the considered process variables in RUM of optical K9 glass using the compressed air as a coolant. Results revealed that SR increases as the ultrasonic power and feed rate increases, whereas it decreases as spindle speed increases. All rights reserved by www.ijirst.org 144 Rotary Ultrasonic Machining of Ni based Alloys (IJIRST/ Volume 3 / Issue 12/ 023) Cong et al. (2012d) used cutting fluid as coolant and reported lower value of machined surface roughness compared to that for cold air under the increased ultrasonic power and tool rotation speed. Comparison of RUM with twist drilling was also made and reported that surface produced with RUM had a lower roughness than that for twist drilling. Factorial Design [12] utilized a 25 (five-variable two-level) full factorial design to study cutting force based on a mechanistic predictive model in RUM of CFRP composites. Main effects as well as interaction effects of five process variables (vibration amplitude, tool rotation speed, feed-rate, abrasive size, and abrasive concentration) on cutting force has been revealed. Taguchi Lee, (2008) conducted an experiment study to compare the effects of ultrasonic and non-ultrasonic on glass lens using rotary ultrasonic machining process. The Taguchi method was utilized to conduct the experimental study and analysis of variance (ANOVA) was performed to study the relative significance of both factors in affecting the surface roughness of glass lens. The final results showed that the process output is greatly influenced by the feed rate rather than the frequency and low feed rate without frequency is identified to be the most optimum factor settings. Abdo et al. (2012) employed Taguchi optimization methodology to optimize Rotary Ultrasonic Machining (RUM) parameters for the milling of zirconia ceramic. A three-level orthogonal array was used to carry out the experiments. The influence of the input parameters such as vibration frequency, vibration amplitude, spindle speed, feed rate, and depth of cut on the surface roughness was investigated. ANOVA results shows that spindle speed, feed rate, vibration amplitude, vibration frequency, and depth of cut affects the surface roughness by 69.76%, 19.20%, 1.88%, 0.49% and 0.02% respectively. Abdo et al. (2013) employed Taguchi optimization methodology to optimize rotary ultrasonic machining parameters for face milling of zirconia ceramic. Finally, verification tests were carried out to compare the predicted values of the outputs with their experimental values to confirm the effectiveness of the Taguchi Optimization. The combination of spindle speed at 6000rpm, feed rate at 150mm/min, frequency at 21.5 kHz, amplitude at 50%, and depth of cut at 0.075mm providing optimum value of MRR of 0.307 mm3/sec. III. MATERIAL AND METHOD Measurement of Roughness Roughness is often a good predictor of the performance of a mechanical component, since irregularities in the surface may form nucleation sites for cracks or corrosion. Roughness is a measure of the texture of a surface. It is quantified by the vertical deviations of a real surface from its ideal form. If these deviations are large, the surface is rough if small, the surface is smooth. Roughness is typically considered to be the high frequency, short wavelength component of a measured surface. The parameters used to characterize a machined surface fall into in two categories: that are roughness Parameters (R_a,R_(q,) R_(z,) R _(t,) R _y) and statistical parameters such as skewness, kurtosis, frequency height distribution. The various roughness parameters are arithmetic average height(R_o) root mean square height (~), peak to valley height (R_t), valley to mean height(R_v)and ten point average height (R_z). However studies have shown that roughness parameters R_a andR_q show limited variation in their value with respect to fiber orientation (Ramulu et al., 1994). So the preferred roughness parameters for representing the surface feature of composites are peak to valley height (R_t) ten point average height (R_z) which is the average of five peak points and five valley points (Ramulu et al. 1999). The role of these roughness parameters is to evaluate the surface Produced by a machining process and to quantify the amount of machining damage for different parameters such as cutting speed, feed rate and depth of cut. It has been shown that lower the value of surface roughness, the better is the quality of machined surface. Roughness values also indicate change in the mechanical properties of machined FRP. Studies have shown that with increasing the roughness, the fatigue strength and impact strength decreases (Ramulu and Arola, 1995). The parameter mostly used for general surface roughness is R a . It measures average roughness by comparing all the peaks and valleys to the mean line and then averaging them all over the entire cut-off length. Cut-off length is the length that the stylus is dragged across the surface, a longer cut-off length will give a more average value and a shorter cut-off length might give a less accurate result over a shorter stretch of surface Measurement of CR and CN Coordinate metrology is a field of metrology that is becoming increasingly popular in the manufacturing industry. Coordinate metrology enables the three-dimensional measurement to be carried out on complex object in a single setup. The instrument used for this purpose is known as the coordinate measuring machine or CMM. In general, the CMM comprises three frames that move along three orthogonal axes, i.e. X-, Y- and Z-axis. Usually, a contact device known as measuring probe is attached to the end of the Z-axis. The displacement along each axis is measured by a linear measurement system and the readings are sent to an electronic controller. The electronic controller is connected to a computer that also enables various types of data processing to be performed. Repeated measurements on similar objects can be done easily by programming the motion of the axes of the machine. This reduces the time taken for measurement and inspection up to 80% to 90%. These machines are made in various sizes and the methods of operation are based on either manual or computer-aided. All rights reserved by www.ijirst.org 145 Rotary Ultrasonic Machining of Ni based Alloys (IJIRST/ Volume 3 / Issue 12/ 023) For the present study a bridge type of CMM is used. In principle, the bridge type CMM has a moving. The measuring probe is fitted to the Z-axis arm and the Z-axis carrier is fitted to the X-axis arm. The X-axis carrier in turn is fitted to the Y-axis arm. Both ends of the Y-axis are supported on the table, usually using air bearings. This type of design offers superior rigidity and thus the CMM has higher precision compared to the horizontal or cantilever arm type. The limitation of this design is that it is difficult to place work onto the table because of the hindrance from the vertical parts of the Y-axis frame. Still, this design is one of the most popular. All CMMs have one or more probes and a method of moving them along three orthogonal axes comparative to the workpiece. Most the probes used at present are the ‘soft’ or touch sensitive types. These types of probes use electronic mechanism to break the circuit when contact between the probe and workpiece occurs. Several types of touch probes are available and the type selected depends on the workpiece material and dimension to be measured. For the present study a ball type probe is used having diameter 1.5 mm. A CMM that is not equipped with a computer is a machine that only enables measurement at only a few selected points. Meaningful readings can only be obtained from detailed calculation. However, the objective of metrology is to analyze individual points that were recorded on the workpiece and obtain information concerning dimensions, shape and position of certain characteristics. This is the main task of a computer in a CMM. Fabrication Process of Metal Bonded Tool In the present study the concentration of the diamonds are taken as 100. The diamond concentration, in conjunction with the diamond particle size, governs the number of cutting points per unit area of the working surface of a tool. The amount of diamond in the tool is based on a scale in which 100 concentration is equivalent to 4.4 ct per 1 cm3. In general, the more friable and abrasive the workpiece, the higher should be the diamond concentration. Outer and inner diameters of the diamond core drill are taken as 8 mm and 6.5 mm respectively. Mixing of diamond abrasive with binder This process may comprise several steps. The most important is mixing of well selected metal-base powders in order to achieve the predetermined chemical composition, particle shape and size distribution. This operation is usually carried out in pendulum motion mixers. Binding agents and lubricants are added to the powder at this stage so as to reduce dust, prevent segregation and minimize wear of steel dies during subsequent cold pressing. When the mixture is to be cold pressed by means of volumetric equipment the matrix powder has to be granulated to ensure required flow and packing characteristics. The diamonds may either be used in as-received condition or coated with a suitable powder prior to final mixing with the matrix powder. Cold pressing Cold pressing is an optional operation in the production of tool components having uniform structure but it becomes mandatory in the conventional cold pressing/sintering process or when multi-layer segments are manufactured by the hot pressing route. A typical ‘sandwich’ consists of three layers which differ in susceptibility to wear and hence a desirable saddle-shaped wear profile is being developed at work. This imparts a self-guiding characteristic to the saw blade and prevents it from deviating in the cut. The cold pressing operations are performed in steel dies at low to medium pressures. There are two types of machinery used within the diamond tool industry. The conventional presses are fitted with vibratory powder dosing chutes and precision scales for the weighing of the correct amount of the mixture to fill the die; whereas the latest designs implement the volumetric filling principle. The gravimetric presses offer higher flexibility necessary to manufacture small quantities of segments. By contrast, despite higher investment costs, volumetric equipment is the preferred option for mass production of tool components due to its greater throughput, longer life and lower cost of pressing consumables. Hot pressing The hot pressing process consists of the simultaneous application of heat and pressure in order to obtain a product nearly free from internal porosity. Compared to the conventional cold pressing/sintering PM route, hot pressing requires 2-3 minute hold at markedly lower temperature, but under a compressive stress, to reach higher density level. Hot pressing is normally accomplished using resistance heating equipment and either steel or graphite moulds. The latter, being in common use, offer higher production rates and, due to the formation of a CO/CO2 reducing atmosphere at elevated temperatures, protect the powders against oxidation. Sintering Sintering is an indispensable step in fabrication of numerous structural and tool PM components. Nonetheless, its application in the manufacture of diamond impregnated tools is limited by restrictions on the composition, mechanical strength and dimensional accuracy of the final product. The conventional cold pressing/sintering route has, however, gain ground in the industrial-scale production of wire saw beads. As opposed to hot pressing, cost savings and higher rates of production achieved by the use of furnace sintering outweigh, in this case, the shortcomings of this operation. De-burring Following the hot consolidation step the segments, or beads, often require cleaning and removing edge residuals. This is carried out during de-burring, which operation is usually performed by means of grinding down. All rights reserved by www.ijirst.org 146 Rotary Ultrasonic Machining of Ni based Alloys (IJIRST/ Volume 3 / Issue 12/ 023) Quality control The quality control of diamond impregnated tool components is usually limited to a hardness test. The Rockwell B test is the most widespread technique due to its simplicity and inexpensiveness. A properly densified matrix-diamond mixture acquires a narrow hardness range. Incompletely densified material has insufficient toughness which results in its poor resistance to wear and diamond retention ability. Therefore, if there is any doubt about the hardness readings, the evaluation of density becomes another important quality check. Finishing operations When the PM processing has been completed, there is a need to attach the diamond impregnated products to a steel support to produce a tool. With the exception of wire saw beads, which are mechanically fixed on a steel carrier cable, either brazing or laser welding is used at this stage. Brazing is widely employed in the manufacture of saw blades, core drills and grinding tools for ‘wet’ applications and allows re-tipping of the steel support; whereas laser welding is mainly used in the production of small diameter, dry cutting circular blades in order to eliminate the possibility of segment detachment. During fabrication of circular saw blades, the steel core must eventually be subjected to an operation of nullifying lateral runout and adding extra stress to stretch its centre section. This counteracts the centrifugal force tending to elongate the rim section of the rotating blade thus making it capable of spinning without wobble. This operation is usually carried out in pendulum motion mixers. Binding agents (Bronze, Copper, Tin, Silicon di-oxide)and lubricants (zirconiciam oxide, cobalt, silicon carbide) are added to the powder at this stage so as to reduce dust, prevent segregation and minimise wear of steel dies during subsequent cold pressing. When the mixture is to be cold pressed by means of volumetric equipment the matrix powder has to be granulated to ensure required flow and packing characteristics. After cold pressing materials send for hot pressing. Compared to the conventional cold pressing/sintering hot pressing requires 2-3 minute hold at markedly lower temperature, but under a compressive stress, to reach higher density level. Hot pressing is normally accomplished using resistance heating equipment and either steel or graphite moulds. Then the materials send for sintering process. Following the hot consolidation step the segments, often require cleaning and removing edge residuals. This is carried out during de-burring, which operation is usually performed by means of grinding down the sharp edges on an abrasive paper or tumbling the segments with a conventional abrasive grit. The Rockwell B test is the most widespread technique due to its simplicity and inexpensiveness. A properly densified matrix-diamond mixture acquires a narrow hardness range. Incompletely densified material has insufficient toughness which results in its poor resistance to wear and diamond retention ability. When the PM processing has been completed, there is a need to attach the diamond impregnated products to a steel support to produce a tool. Brazing is widely employed in the manufacture of core drills for ‘wet’ applications. Experimentation If there is curvature found in the system, then a polynomial of second or more degree must be used, such as the second-order model [13]. Response surface methodology (RSM) is utilized for experimentation of second phase when first order model is insignificant. The entire experimentation process has been carried out on rotary ultrasonic machine set-up (Series10 Knee-mill, Sonic Mill, Albuquerque, NM, USA Before machining of RUM, a sample extracted from workpiece is characterized using energy dispersive X-ray (EDX) test, and scanning electron microscopy (SEM). The SEM microstructure of the inconel 718 (before machining) at 1000× and 3000×, is depicted in Figure 2. This reveals that the grain size is almost uniform throughout the surface. The presence of various constituents of inconel 718 has been confirmed by performing EDX analysis. It has also been observed from EDX analysis that the majority of portion is covered with nickel- chromium and its compound, Figure 2 SEM microstructure of Inconel 718 alloy surface (before machining) at 1000X. Fig. 2: All rights reserved by www.ijirst.org 147 Rotary Ultrasonic Machining of Ni based Alloys (IJIRST/ Volume 3 / Issue 12/ 023) The inner and outer diameters of the hollow tool were 8 mm and 6.5 mm, respectively. One replication is used to conduct the experimentations and mean value average of the readings is taken for computation of MR analysis. The main advantages of taking replication are that it allows the experimenter to obtain an estimate of the experimental error. This estimate of error becomes a basic unit of measurement for determining whether observed differences in the data are really statistically different. Second, replication permits the experimenter to obtain a more precise estimate of the parameter [6]–[11], [14]–[18], [18]–[23]. The range of the four selected variables as input parameters are shown in Table 1. For four variables (n = 4) and two levels (low (-) and high (+)), the total number of experiments 21 is determined by the expression: 2n-1 (24-1 = 8: factor points) + 2×n (2 × 4: 8axial points) + 5 (center points), as shown in Tables 1. A full second-order polynomial model is obtained by multiple regression technique for four factors by using ANOVA. In developing the regression equation developed by Box and Hunter, the test factors are coded according to the following equation: X  X i0 xi  i X i (1) Where x is the coded value of the ith independent variable, X the natural value of the ith independent variable, X the natural value of the ith independent variable at the center point, and ∆X is the step change value. Y  b0   bi x i    bij x i x j   bii x i  e k 1 k k k 2 i 1 i 1 j  2 i 1 (2) Where Y is the predicted response, b and the offset term, b the linear effect, b represents square effect and b is the interaction effect. x represents the significant independent and the mathematical relationship of the response Y on these variables can be approximated by second order equation as shown below: (3) Y =b +b x +b x +b x +b x +b x +b x +b x +b x +b x x +b x x Where Y is the predicted response variable, b is the constant, b , b , b and b are the linear coefficients, b and b are the cross-product coefficients, and b , b , b and b are the quadratic coefficients. Design of experiments for RUM Design of experiments (DOE), for all three tool profiles are considered by response surface methodology using central composite rotatable design (CCD). The four input process parameters viz. tool rotation; feed rate; ultrasonic power; and abrasive diamond grit size are mentioned in Table 1. Table – 1 Factors and their levels Sr. No Symbol Input factos 1 2 3 4 A B B D Spindle speed Feed Rate Power Rating Diamond abrasive size 4200 0.01 55 80 Low 4600 0.0125 60 100 Level Center 5000 0.0150 65 120 High 5400 0.0175 70 140 Units 5800 0.02 75 160 RPM mm/sec % mesh IV. RESULTS AND DISCUSSION The main experiments have been designed by using a design of experiments (DOE) technique called “Response Surface Methodology” through central composite design (CCD). This chapter concentrates on analysis of results of main experimentation in order to identify individual as well as interaction effects of process parameters on various responses i.e. machining rate, tool wear, roughness, conicity and circularity. The experimental results for various process responses are also presented and discussed. The significance of different process variables have been analyzed by conducting ANOVA test. A statistical calculation is performed to check adequacy of fitted model and carry out regression and graphical analysis through ANOVA. Analysis of variance for MR The experimental results for MR are analyzed using CCD [25] technique. Analysis of variance is carried out to statistically analyze the results. To check the adequacy of the model, three different tests, the sequential model sum of squares, lack-of-fit test, and model summary statistics are performed. The results indicate that the quadratic model in all the characteristics does not show significant lack of fit, hence tests recommend the adequacy of the quadratic model. The results of the quadratic model analyzed using ANOVA reveals that there are many insignificant terms in the model. Therefore, the model reduction is performed by a backward elimination process to improve the model. It eliminates the unimportant terms in order to adjust the fitted quadratic model while sustaining the hierarchy of the regression model. The hierarchy of different models is preserved to develop the mathematical models as it is observed that only hierarchical models are invariant under linear transformations [Piexto, 1987]. Principle of Hierarchy explains that; although a factor as a main effect is found to be insignificant as regards to its contribution towards the response parameter, but; if its higher order terms viz. interaction or quadratic terms are significant, main effect will be included in the analysis as significant parameter. All rights reserved by www.ijirst.org 148 Rotary Ultrasonic Machining of Ni based Alloys (IJIRST/ Volume 3 / Issue 12/ 023) The normal probability which reveals that more than 90 % of residuals are declining within ± 3 sigma limit and residuals are settled by the straight line. Fig. 6b also reveals that the experimental values are very close to the predicted ones for the quadratic model. It is found that analysed results in ANOVA are reliable, as both the plots (Figs. 6a, 6b) satisfy prediction potential criteria and the error normality. The F value is the fisher value of the model that calculates the ratio of mean square of the model and the residual mean square. A specific source of deviation is significant when the computed F value at a particular confidence level is larger than the tabulated F value at the same level of confidence. The model F-value 556.61 and P-value less than 0.05 clear that the obtained model is significant for machining rate, considering the confidence level 95 %. Generally, a model with higher Fvalue and lower p- value is selected. Analysis of variance for Ra The investigation results shown in Figure 2 are analysed for Ra. On the basis of fitted value, the adequacy of the quadratic model is proposed by design expert package. Analysis of variance is performed to analyze the obtained outcomes of the quadratic model. From the results it is found that there is lot of non-significant model terms present in the model. A backward elimination method is utilised to remove the non-significant model terms that present in the quadratic model. The normal probability plot of the residuals for Ra which reveals that more than 90 % of residuals are declining within ± 3 sigma limit and residuals are settled by the straight line. It can also be seen that for Ra, the experimental values are chasing the predicted ones. Figure 2 shows the results of ANOVA for the confirmation of the reliability. The significance of the model is shown in this figure with the 82.76 F value. The resulted P- value less than 0.0001 points to the significance of the model terms. In the present study, the model terms A, is found the most significant term of RUM followed by A, D, A, C, AC, BC, CD, and BD for Ra. The lack-of-fit value obtained from the model is 19.03 which show that its value is insignificant relative to pure error. There is only 13.07% chance that a lack-of-fit could be occurred due to noise. In order to fit the actual experimental values, the insignificant ‘lack of fit’ is fine. Results shows that the R2 value for Ra is 0.9854. It explains that there is less variation between predicted value and experimental value of Ra. As far as other R2 statistics are concerned, there is a good agreement in the value of Pred R2 (0.9986), and Adj R2 (0.9735). Furthermore, the Adeq Precision represents the signal-to-noise ratio. For the present study Adeq Precision is found 99.15 for the model. Thus, the developed model can be utilized to predict the values through the navigation of the design space. From the obtained model for Ra, the values of R2 (0.9854) and Adeq Precision (35.581) shows significance for fitting and prediction of the experimental results. The equation (7) defines the regression model for roughness: Effect of process parameters on “MR” In the RUM of nickel alloy, main effects of controllable machining parameters namely; tool rotation (A), feed rate (B), ultrasonic power (C), abrasive grit size (D), interaction terms AB, second order term of feed rate (B2), ultrasonic power (C2), abrasive grit size (D2), are found to possess significant effects on the MR. MR is found to be increased suddenly as feed rate level incremented from 0.01 mm/s to 0.02 mm/s. Tool rotation, feed rate, ultrasonic power, abrasive grit size is also reported with gradual impact on MR. The observed enhancement rate in MR with feed rate is higher than with other parameters, i.e. tool rotation, feed rate, ultrasonic power, abrasive grit size, as shown in figure 3 for MR. Fig. 3: Two variables interactive plot for MR The combined influence of feed rate and spindle speed on MR is represented in Figure 3 (a). The increment in feed rate causes into the deep indentation of the diamond abrasives, hence improved MR has been reported. A dramatic effect of diamond impregnated tool rotation is observed during RUM process. MR is also found to be degrading with a combination of low feed rate and tool rotational speed increments from 4200 rpm to 5800 rpm and . But MR is also found to be enhanced with a combination of high feed rate and tool rotation increments from 4200 rpm to 5800 rpm. The reason probably that the contact length the diamond abrasive, i.e. the distance travelled through an indentation diamond abrasive while abrasive particle touched the workpiece surface, also increased. Furthermore, increased spindle speed also causes an increment in the volume of All rights reserved by www.ijirst.org 149 Rotary Ultrasonic Machining of Ni based Alloys (IJIRST/ Volume 3 / Issue 12/ 023) indentation proportionally, which caused into the higher material removal rate. Figure 3 (b) illustrates the combined effects of abrasive grit size and tool rotation on MR. Big diamond abrasive grit size means lower the value of mesh size. The MR is observed to rise gently as tool rotation level incremented from 4200 rpm to 5800 rpm, whereas steeply fall in MR attained as abrasive grit size decremented from 80 mesh to 120 mesh and steeply rise attained as abrasive grit size decremented from 120 mesh to 160 mesh. In the rotary ultrasonic machining process, machining parameter termed as- “ultrasonic power”, which directs the amplitude of vibration, also influences the rate of material removal. The MR increases as ultrasonic power increases from 55% to 75%. Effect of process parameters on “Ra” In the RUM of Inconel 718, main effects of variables namely; tool rotation (A), feed rate (B), abrasive grit size of tool (D), interaction terms (AC), (BC), (BD), (CD), second order term of feed rate (D2) are found to have significant effects on the machining surface. Tool rotation (A), feed rate (B) and abrasive grit size of the tool (D) is observed to contribute approximately 90% of the overall disparity in the response data. Fig. 4 shows the effects of all factors on the roughness of the machining surface. The Ra is found to increase steeply as feed rate is incremented from 0.01 mm/s to 0.02 mm/s. Higher Ra has revealed as feed rate of diamond impregnated core drill tool increases. The increment in feed rate causes into the increased indentation depth of the diamond abrasives which further promotes the rough cutting of work surface (chipped out and dipper groove region), hence increased Ra is observed [24]–[27]. Fig. 4: Two variables interactive plot for Ra Fig. 4 illustrated two factors interactive effect plots while machining Inconel 718 with the RUM process. Fig. 4 (a) illustrates the combined effects of ultrasonic power and tool rotation on Ra. The Ra is observed to fall (1.1391 micron - 0.7917 micron) as tool rotation level improved from 4200 rpm to 5800 rpm. As tool rotation enhances from 4200 rpm to 5800 rpm, the chances of enhancing the grinding action which further promotes the finess in the machining surfaces. The very slow increment (1.010 micron - 1.021 micron) in Ra is observed as ultrasonic power incremented from 55% to 75% [27]. The combined influence of feed rate and ultrasonic power on Ra is represented in Fig. 4 (b). Higher Ra is revealed as feed rate of diamond impregnated core drill tool increases. The increment in feed rate causes into the increased indentation depth of the diamond abrasives which further promotes the rough cutting of work surface (chipped out and dipper groove region), hence increase in surface roughness is observed. The combined influence of feed rate and abrasive grit size of diamonds on Ra is represented in Fig. 4 (c). Higher Ra is revealed as feed rate of diamond impregnated core drill tool increases. With increase in feed rate, Ra increases steeply, whereas Ra is reduced at higher levels of abrasive grit size which may be due to the conventional grinding action of the abrasive tool. All rights reserved by www.ijirst.org 150 Rotary Ultrasonic Machining of Ni based Alloys (IJIRST/ Volume 3 / Issue 12/ 023) The combined influence of ultrasonic power and abrasive grit size on Ra is described in Fig. 4 (d). With increase in ultrasonic power, Ra decreases steeply, whereas Ra first decreases as abrasive grit size deceases from 80 mesh to 120 mesh, and then increases from 120 mesh to 160 mesh. V. CONCLUSIONS An investigation has been conducted to study the influence of several process parameters on Ra and MR in RUM of Nickel alloy. 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