Abdo Basem M A, Alkhalefah Hisham, Moiduddin Khaja, Abidi Mustufa Haider
Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia.
Materials (Basel). 2020 Nov 25;13(23):5343. doi: 10.3390/ma13235343.
The machining of ceramic materials is challenging and often impossible to realize with conventional machining tools. In various manufacturing applications, rotary ultrasonic milling (RUM) shows strengths, in particular for the development of high-quality micro-features in ceramic materials. The main variables that influence the performance and price of the product are surface roughness, edge chipping (EC), and material removal rate (MRR) during the processing of ceramics. RUM has been considered in this research for the milling of micro-pockets in bioceramic alumina (AlO). Response surface methodology in the context of a central composite design (CCD) is being used to plan the experiments. The impacts of important RUM input parameters concerning cutting speed, feed rate, depth of cut, frequency, and amplitude have been explored on the surface roughness in terms of arithmetic mean value (Ra), the EC, and the MRR of the machined pockets. The main effect and the interaction effect of the implemented RUM parameters show that by providing a lower feed rate and cutting depth levels and elevated frequency and cutting speed, the Ra and the EC can be minimized. At greater levels of feed rate and cutting depth, higher MRR can be obtained. The influence of RUM input parameters on the surface morphology was also recorded and analyzed using scanning electron microscopic (SEM) images. The study of the energy dispersive spectroscopy (EDS) shows that there is no modification in the alumina bioceramic material. Additionally, a multi-response optimization method has been applied by employing a desirability approach with the core objectives of minimizing the EC and Ra and maximizing the MRR of the milled pockets. The obtained experimental values for Ra, EC, and MRR at an optimized parametric setting were 0.301 µm, 12.45 µm, and 0.873 mm/min respectively with a combined desirability index value of 0.73.
陶瓷材料的加工具有挑战性，使用传统加工工具往往难以实现。在各种制造应用中，旋转超声铣削（RUM）展现出优势，尤其适用于陶瓷材料中高质量微观特征的加工。在陶瓷加工过程中，影响产品性能和价格的主要变量是表面粗糙度、边缘崩裂（EC）和材料去除率（MRR）。本研究考虑采用旋转超声铣削加工生物陶瓷氧化铝（AlO）中的微槽。采用中心复合设计（CCD）背景下的响应面方法来规划实验。研究了旋转超声铣削的重要输入参数（切削速度、进给速度、切削深度、频率和振幅）对加工微槽的表面粗糙度（以算术平均值（Ra）表示）、边缘崩裂和材料去除率的影响。所实施的旋转超声铣削参数的主效应和交互效应表明，通过提供较低的进给速度和切削深度水平以及提高频率和切削速度，可以使Ra和边缘崩裂最小化。在较高的进给速度和切削深度水平下，可以获得更高的材料去除率。还使用扫描电子显微镜（SEM）图像记录并分析了旋转超声铣削输入参数对表面形貌的影响。能量色散光谱（EDS）研究表明，生物陶瓷氧化铝材料没有发生变化。此外，采用了一种多响应优化方法，采用期望度方法，核心目标是最小化边缘崩裂和Ra，并最大化铣削微槽的材料去除率。在优化参数设置下，获得的Ra、边缘崩裂和材料去除率的实验值分别为0.301 µm、12.45 µm和0.873 mm/min，综合期望度指数值为0.73。
