Outline

  • Abstract
  • Keywords
  • 1. Introduction
  • 2. Methodology
  • 3. Mechanism of Tool Wear
  • 4. Results and Discussion
  • 5. Conclusions
  • Acknowledgement
  • References

رئوس مطالب

  • چکیده
  • کلیدواژه ها
  • مقدمه
  • متدولوژی
  • مکانیسم فرسایش ابزار
  • نتایج و بحث
  • نتیجه گیری ها

Abstract

Form accuracy of a machined component is one of the performance indicators of a machining process. Ultrasonic micromachining is one such process in which the form accuracy of the micromachined component significantly depends upon the form stability of tool. Unlike micromachining, a very small amount of tool wear in micromachining could lead to considerable changes in the form accuracy of the machined component. Appropriate selection of tool material is essential to overcome this problem. The present study discusses the effect of tool material, abrasive size and step feed in fabrication of microchannels by ultrasonic machining on borosilicate glass. Development of microchannels using ultrasonic micromachining were rarely reported. It was observed that tungsten carbide tool provided a better form accuracy in comparison to the microchannel machined by stainless steel tool. The tool wear mechanism in both materials is proposed by considering scanning electron micrographs of the tool as evidence. A one factor at a time approach was used to study the effect of various process parameters.

Keywords: - - -

Conclusions

  1. The relatively ductile nature of SS tool and lower hardness while comparison to WC tool, results in higher wear of SS tool making it unsuitable for layer by layer ultrasonic micromachining for precision application.
  2. Microchannel width increased with use of larger abrasive particles. However the depth of the microchannel was mainly dependent upon the step feed.
  3. The tool wear can be divided into three zones. The zone-1, existing in the working gap involves mainly hammering and cavitation action. Zone-2 prevails at the edges of the tool. The main wear mode here is hammering and abrasion. Zone-3 involves the lateral gap, where abrasion and rolling of abrasive particles is main mode of wear.
  4. In WC tool the zone-3 wear is responsible for deciding the form accuracy. Whereas in SS tool, the zone-2 wear decides the form accuracy. The built up edge developed spreads the horizon of zone-2, resulting in dimensional inaccuracy.
  5. The mechanism of strain hardening in SS tool is also responsible for affecting the form accuracy of developed microchannel. But in case of WC tool strain hardening is negligible compared to SS tool
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