Process Parameters

Following are the parameters which determine the material removal rate and shown graphically below.

• Frequency
• Amplitude
• Static loading (feed force)
• Hardness ratio
• Grain diameter
• Abrasive
• Viscosity of fluid

We can observe the effect of process parameters on material removal rate in Figure 23.4. With increasing frequency of ultrasonic vibration, material removal rate increases. The material removal rate increases with increasing amplitude and the rate of increase in material removal rate increases with increasing frequency. When feed force increases, the material removal rate increases up to optimum level then starts to decrease. When the ratio of work harness and tool hardness increases the material removal rate decreases sharply initially and then slowly. The material removal rate also depends on grain size of slurry; if grain size increases, the material removal rate increases up to some level then starts to decrease. Increasing the abrasive concentration in the slurry increases the material removal rate. If the viscosity of fluid carrying the slurry increases, the material removal rate decreases sharply and then slowly.

Figure 23.4 Effect of Process Parameters on Material Removal Rate in USM