Developments in Ceramic Materials Research

In: Developments in Ceramic Materials Research ISBN 978-1-60021-770-8
Editor: Dena Rosslere, pp. 35-52 © 2007 Nova Science Publishers, Inc.
Chapter 2
RECENT ADVANCES IN ROTARY ULTRASONIC
MACHINING OF CERAMICS
Z. C. Li * , Z. J. Pei * and C. Treadwell **
* Department of Industrial and Manufacturing Systems Engineering,
Kansas State University, Manhattan, KS 66506
** Sonic-Mill Company
7500 Bluewater Road N.W. Albuquerque, NM 87121
ABSTRACT
Rotary ultrasonic machining (RUM) is one of the nontraditional machining processes
for ceramics. This chapter overviews the recent advances in RUM of ceramics since
2001. It first reports the progress on quality improvement of RUM machined parts –
reduction and elimination of edge chipping in RUM of ceramics. After discussing the
effects of RUM process parameters (spindle speed, feedrate, ultrasonic vibration power,
and grit size) on the edge chipping thickness, practical ways to reduce the edge chipping
are presented.
It then presents recent studies on the effects of coolant type, pressure, and delivery
mode (continuous versus intermittent) on cutting force and surface roughness when RUM
of ceramics.
Finally, it reports the exploratory efforts to apply RUM to machine silicon carbide
and ceramic matrix composites (CMC). It discusses the effects of RUM process
parameters (spindle speed, feedrate, ultrasonic vibration power, and grit size etc.) on
cutting force, surface roughness, tool wear, and chipping size.
1. INTRODUCTION
Thanks to their superior properties in hardness, strength, and resistance to wear and
corrosion, advanced ceramics are attractive for many industrial applications [Inasaki and
Nakayama, 1986; Zhang and Howest, 1994; Malkin and Hwang, 1996; Zeng et al., 2005].
However, their high machining cost is a major barrier for the widespread utilizations of