Modeling the material removal rate in ultrasonic machining of titanium using dimensional analysis

Titanium is known as the metal of the future because of its excellent combination of properties such as high strength-to-weight ratio, low thermal conductivity, and high corrosion resistance. Machining of titanium, however, is considered as cumbersome with the conventional manufacturing practices, and there is a critical need of developing and establishing cost-effective methods of machining. This investigation is focused on exploring the use of ultrasonic machining, a nontraditional machining process for commercial machining of pure titanium (American Society for Testing and Materials grade-I) and evaluation of material removal rate under controlled experimental conditions. The optimal settings of parameters are determined through experiments planned, conducted, and analyzed using Taguchi method. An attempt has been made to construct a micro-model for prediction of material removal rate in ultrasonic machining of titanium using dimensional analysis. The predictions from this model have been validated by conducting experiments. The microstructure of the machined surface under different experimental conditions has been studied using scanning electron microscopy. A relation was established between the mode of material removal and the energy input rate corresponding to the different process conditions.