Developments in Ceramic Materials Research

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36 Z. C. Li, Z. J. Pei and C. Treadwell advanced ceramics [Zhang and Howest, 1994; Malkin and Hwang, 1996; Zeng et al., 2005]. Therefore, it is desirable to develop more cost-effective machining processes for advanced ceramics. Rotary ultrasonic machining (RUM) is one of the cost-effective processes for machining advanced ceramics. It combines the material removal mechanisms of diamond grinding and ultrasonic machining [Legge, 1964; Legge, 1966]. Figure 1 illustrates the RUM process. A rotating diamond core drill is ultrasonically vibrated and fed to the workpiece. Table 1 summarizes the types of advanced ceramics machined by RUM up to 2001. Much efforts have been exerted to study the RUM process experimentally and theoretically. Reported studies on RUM up to 2001 are summarized in Table 2. More comprehensive reviews on these reported studies are in the literature [Pei et al., 1995 a ; Li et al., 2004]. This chapter reports the recent advances in RUM of advanced 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. Then, 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 are presented. Finally, it reports the exploratory efforts to apply RUM to machine silicon carbide and ceramic matrix composites (CMC). Figure 1. Illustration of RUM.
Recent Advances in Rotary Ultrasonic Machining of Ceramics 37 Ceramic material References Table 1. Ceramic materials machined by RUM till 2001 Alumina Anantha Ramu et al., 1989, Zhang et al., 1995 Canasite Khanna et al., 1995 Glass Lunzer, 1973; Anonymous, 1966; Anonymous, 1973 Silicon nitride Cleave, 1970; Dam et al., 1995 Zirconia Anantha Ramu et al., 1989; Prabhakar, 1993; Pei, 1995; Pei et al., 1995 b ; Pei et al., 1995 c ; Pei and Ferreira, 1998 Table 2. Reported studies on RUM till 2001 Study Reference Material removal mechanism (brittle/ductile removal modes) Material removal models based upon different material removal modes Effects of process parameters (rotating speed; feedrate; ultrasonic vibration amplitude and frequency; diamond type, size and concentration; bond type for the cutting tool, etc.) on the performances (material removal rate, cutting force, surface roughness, etc.) Prabhakar et al., 1993; Spur and Holl, 1997; Zhang et al., 1995 Pei, 1995; Pei et al., 1995 a ; Pei et al., 1998 Petrukaha et al., 1970; Markov and Ustinov, 1972; Markov and Ustinov, 1977; Prabhakar, 1992; Spur et al., 1997; Kubota et al., 1997 Extension to face milling Pei and Ferreira, 1999 Extension to disk grinding Khanna et al., 1995 Extension to complex contour machining Uhlmann et al., 1999 ; Ya et al., 2001
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