Rotary ultrasonic machining of hard-to-machine materials

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dc.contributor.author Churi, Nikhil
dc.date.accessioned 2010-02-10T16:03:22Z
dc.date.available 2010-02-10T16:03:22Z
dc.date.issued 2010-02-10T16:03:22Z
dc.identifier.uri http://hdl.handle.net/2097/2509
dc.description.abstract Titanium alloy is one of the most important materials used in major segments of industries such as aerospace, automobile, sporting goods, medical and chemical. Market survey has stated that the titanium shipment in the USA has increased significantly in last two decades, indicating its increased usage. Industries are always under tremendous pressure to meet the ever-increasing demand to lower cost and improve quality of the products manufactured from titanium alloy. Similar to titanium alloys, silicon carbide and dental ceramics are two important materials used in many applications. Rotary ultrasonic machining (RUM) is a non-traditional machining process that combines the material removal mechanisms of diamond grinding and ultrasonic machining. It comprises of a tool mounted on a rotary spindle attached to a piezo-electric transducer to produce the rotary and ultrasonic motion. No study has been reported on RUM of titanium alloy, silicon carbide and dental ceramics. The goal of this research was to provide new knowledge of machining these hard-to-machine materials with RUM for further improvements in the machining cost and surface quality. A thorough research has been conducted based on the feasibility study, effects of tool variables, effects of machining variables and wheel wear mechanisms while RUM of titanium alloy. The effects of machining variables (such as spindle speed, feed rate, ultrasonic vibration power) and tool variables (grit size, diamond grain concentration, bond type) have been studied on the output variables (such as cutting force, material removal rate, surface roughness, chipping size) and the wheel wear mechanisms for titanium alloy. Feasibility of machining silicon carbide and dental ceramics is also conducted along with a designed experimental study. en_US
dc.description.sponsorship The Boeing Company; Sonic-Mill Corporation; N.B.R. Diamond Tool Corporation en_US
dc.language.iso en_US en_US
dc.publisher Kansas State University en_US
dc.subject rotary ultrasonic machining en_US
dc.subject titanium en_US
dc.subject silicon carbide en_US
dc.subject dental ceramics en_US
dc.subject wheel wear mechanisms en_US
dc.subject force model en_US
dc.title Rotary ultrasonic machining of hard-to-machine materials en_US
dc.type Dissertation en_US
dc.description.degree Doctor of Philosophy en_US
dc.description.level Doctoral en_US
dc.description.department Department of Industrial & Manufacturing Systems Engineering en_US
dc.description.advisor Zhijian Pei en_US
dc.subject.umi Engineering, Aerospace (0538) en_US
dc.subject.umi Engineering, Automotive (0540) en_US
dc.subject.umi Engineering, Industrial (0546) en_US
dc.subject.umi Engineering, Mechanical (0548) en_US
dc.date.published 2010 en_US
dc.date.graduationmonth May en_US


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