Rotary ultrasonic machining of aluminium oxide ceramics: designed experiments

There is a crucial need of reliable and cost-effective manufacturing method for advanced ceramics because of the limitations of conventional processes. 

These materials are used in a large number of critical engineering applications due to its hardness, high wear resistance and thermal-chemical stability. In this point, Rotary Ultrasonic Machining (RUM) process appears as a recognised an efficient machining solution. RUM uses a superabrasive tool together with an axial vibrating motion in ultrasonic region (∼20 kHz). The tool also rotates and feeds against the workpiece producing beneficial effects such as reduction of cutting forces, improved surface roughness, less tool wear, higher MRR, etc. This paper presents the performance of Ultrasonic Machining (USM) of Aluminium Oxide using a design of experiments. The principles and real benefits of RUM process for this ceramic material are assessed.