Investigation of the Circularity and Conicity of Super Alloy During Rotary Ultrasonic Machining

Manufacturing industries are moving toward super alloys owing to their unique features. In this article, the performance analysis of nickel-based super alloys has been studied on rotary ultrasonic machining (RUM) by varying the tool shapes and abrasive size of the diamond. The output quality of the machined part has been evaluated in terms of conicity and circularity of the hole. The machining process has been carried out by considering all the necessary RUM parameters like tool rotation, tool feed rate and ultrasonic power. The experimental setup validated that the lower value of conicity and circularity can be obtained at: tool rotation 4600rpm, feed rate 0.013843mm/s, ultrasonic power 60% abrasive size 140 mesh and using slotted tool. The variation in the abrasive size and the tool shapes has a significant effect on the performance of the machining.