Investigation on Improvement of Surface Roughness Using Rotary Ultrasonic Assisted Machining Technique for Hardened Steel Material / Azlan Ramli...[et al.]

Ramli, Azlan and Raja Abdullah, Raja Izamshah and Abu Bakar, Mohd Hadzley and Kasim, Mohd Shahir and A. Rahman, Muhamad Arfauz and Mohd Zakaria, Muhammad Akmal (2017) Investigation on Improvement of Surface Roughness Using Rotary Ultrasonic Assisted Machining Technique for Hardened Steel Material / Azlan Ramli...[et al.]. Journal of Mechanical Engineering (JMechE), SI 3 (1). pp. 118-134. ISSN 18235514

Abstract

Several challenges are faced by manufacturers producing best surface finish especially for the mould and die applications. In general, most of the mould and die material are made from hardened steel (~40-60 HRc). The high strength of these materials reduced the capability of the conventional machining technique. Poor machined surface and high tool wear rate are among the problems associated with the conventional machining of this material. To overcome these problems, this paper proposed a hybrid machining process by adding an ultrasonic transducer to the normal tooling system namely ultrasonic assisted machining (UAM). Experimental work consisted of a comparison between ultrasonic assisted machining and conventional machining for different parameters namely cutting speed, feed rate and machining depth in order to validate the effectiveness of the proposed technique in improving the surface roughness value for machining hardened AISI D2 material. 2 level factorial design with 3 factors was employed as the technique of design of experiment (DOE). The machining test showed that the presence of rotary ultrasonic assisted vibration significantly improved the machined surface roughness with up to 85% reduction in Ra value compared to the conventional machining process with the same cutting conditions. In addition, the macroscopic observation of machined surface showed that the surface produced from ultrasonic machining was uniform with consistent peak to peak value which improved the surface finish.

Metadata

Item Type: Article
Creators:
Creators
Email / ID Num.
Ramli, Azlan
azlan_ramli@yahoo.com
Raja Abdullah, Raja Izamshah
UNSPECIFIED
Abu Bakar, Mohd Hadzley
UNSPECIFIED
Kasim, Mohd Shahir
UNSPECIFIED
A. Rahman, Muhamad Arfauz
UNSPECIFIED
Mohd Zakaria, Muhammad Akmal
UNSPECIFIED
Subjects: T Technology > TJ Mechanical engineering and machinery
Divisions: Universiti Teknologi MARA, Shah Alam > Faculty of Mechanical Engineering
Journal or Publication Title: Journal of Mechanical Engineering (JMechE)
UiTM Journal Collections: UiTM Journal > Journal of Mechanical Engineering (JMechE)
ISSN: 18235514
Volume: SI 3
Number: 1
Page Range: pp. 118-134
Keywords: ultrasonic assisted machining (UAM); AIS; experiment (DOE)
Date: 2017
URI: https://ir.uitm.edu.my/id/eprint/38538
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