Title: Rotary ultrasonic machining of silicon carbide: designed experiments

Authors: Nikhi J. Churi, Z.J. Pei, Dustin C. Shorter, Clyde Treadwell

Addresses: Department of Industrial and Manufacturing Systems Engineering, Kansas State University, Manhattan, KS 66506, USA. ' Department of Industrial and Manufacturing Systems Engineering, Kansas State University, Manhattan, KS 66506, USA. ' Department of Industrial and Manufacturing Systems Engineering, Kansas State University, Manhattan, KS 66506, USA. ' Sonic-Mill, 7500 Bluewater Road NW, Albuquerque, NM 87121, USA

Abstract: Silicon carbide (SiC) has found a variety of engineering applications due to its superior properties. However, it is still desirable to study cost-effective processes to machine silicon carbide. This paper presents the results of a designed experimental investigation into Rotary Ultrasonic Machining (RUM) of silicon carbide. A four-variable two-level full factorial design was employed to reveal main effects as well as interaction effects of four process variables (spindle speed, feedrate, ultrasonic power and grit size). The process outputs studied include cutting force, surface roughness and chipping size.

Keywords: ceramics; chipping size; cutting force; design of experiments; DOE; grinding; rotary ultrasonic machining; RUM; surface roughness; silicon carbide; factorial design; spindle speed; feedrate; ultrasonic power; grit size.

DOI: 10.1504/IJMTM.2007.014154

International Journal of Manufacturing Technology and Management, 2007 Vol.12 No.1/2/3, pp.284 - 298

Published online: 23 Jun 2007 *

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