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Prediction of Surface Roughness on Ultrasonic Machining Of Titanium Using Response Surface Me thodology

Nitesh Dhar Badgayan, Ankan Mishra, Sameer Panda

Materials are ubiquitous, no society no matter how primitive or how sophisticated its technology, has ever existed without use and application of a variety of materials. Titanium and its alloys are extensively used in aerospace mainly in airframe construction because of their excellent combination of high specific strength which is maintained at elevated temperature then fracture resistance characteristics and their exceptional resistance to corrosion. Conventional machining of titanium and its alloys is cumbersome owing to several inherent properties of the material. Titanium is very chemically reactive and therefore has a tendency to weld to cutting tool during machining thus leading to premature tool failure Its low thermal conductivity increases the temperature at tool work interface thus affecting tool life adversely, which result difficult to machine titanium and its alloy by conventional machining methods. Also Very few literature is available on context of Surface Roughness analysis of Titanium as per as Ultrasonic Machining of Titanium is concerned. This paper presents investigation of Surface Roughness on Ultrasonic Machining (USM) of titanium (ASTM Grade 2), an attempt has been made to model response variable i.e. Surface Roughness in USM process using Response Surface Methodology (RSM) with DESIGN EXPERT 8.0 software. Two parameters i.e. .Grit Size, Power each at two levels has been varied to investigate their effect on Surface Roughness. The Analysis of Variance (ANOVA) has been applied to identify significance of developed model. The test result confirms validity and adequacy of developed RSM model.