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Materials 2017, 10(9), 1069; doi:10.3390/ma10091069

Drilling High Precision Holes in Ti6Al4V Using Rotary Ultrasonic Machining and Uncertainties Underlying Cutting Force, Tool Wear, and Production Inaccuracies

1
Industrial Engineering Department, College of Engineering, King Saud University, P.O. Box 800, Riyadh 11421, Saudi Arabia
2
Faculty of Engineering, Kitami Institute of Technology, 165 Koen-cho, Kitami, Hokkaido 090-8507, Japan
*
Author to whom correspondence should be addressed.
Received: 3 July 2017 / Revised: 18 August 2017 / Accepted: 5 September 2017 / Published: 12 September 2017
(This article belongs to the Section Manufacturing Processes and Systems)
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Abstract

Ti6Al4V alloys are difficult-to-cut materials that have extensive applications in the automotive and aerospace industry. A great deal of effort has been made to develop and improve the machining operations of Ti6Al4V alloys. This paper presents an experimental study that systematically analyzes the effects of the machining conditions (ultrasonic power, feed rate, spindle speed, and tool diameter) on the performance parameters (cutting force, tool wear, overcut error, and cylindricity error), while drilling high precision holes on the workpiece made of Ti6Al4V alloys using rotary ultrasonic machining (RUM). Numerical results were obtained by conducting experiments following the design of an experiment procedure. The effects of the machining conditions on each performance parameter have been determined by constructing a set of possibility distributions (i.e., trapezoidal fuzzy numbers) from the experimental data. A possibility distribution is a probability-distribution-neural representation of uncertainty, and is effective in quantifying the uncertainty underlying physical quantities when there is a limited number of data points which is the case here. Lastly, the optimal machining conditions have been identified using these possibility distributions. View Full-Text
Keywords: rotary ultrasonic machining; drilling; Ti6Al4V; possibility distribution; uncertainty quantification rotary ultrasonic machining; drilling; Ti6Al4V; possibility distribution; uncertainty quantification
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. (CC BY 4.0).

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MDPI and ACS Style

Chowdhury, M.A.K.; Sharif Ullah, A.M.M.; Anwar, S. Drilling High Precision Holes in Ti6Al4V Using Rotary Ultrasonic Machining and Uncertainties Underlying Cutting Force, Tool Wear, and Production Inaccuracies. Materials 2017, 10, 1069.

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