Mathematical modeling of tool wear rate in ultrasonic machining of titanium

Ultrasonic machining is a mechanical material removal process used to erode holes and cavities in hard or brittle workpiece by using shaped tools, high-frequency mechanical motion, and an abrasive slurry. In the present study, outcome of the Taguchi model has been used for developing a mathematical model for tool wear rate; using Buckingham’s π-theorem for stationary ultrasonic machining of titanium and its alloys. Six input parameters, namely, tool material, power rating, slurry type, slurry temperature, slurry concentration, and slurry grit size were selected to give output in form of tool wear rate. This study will provide main effects of these variables on tool wear rate and will shed light on the tool wear mechanism in ultrasonic machining of titanium and its alloys. The comparison with experimental results will also serve as further validation of model.