A systematic survey of RUM process parameter optimization and their influence on part characteristics of nickel 718

Dipesh Popli; Usha Batra; Velaphi Msomi; Shubham Verma

doi:10.1038/s41598-023-28674-1

A systematic survey of RUM process parameter optimization and their influence on part characteristics of nickel 718

Sci Rep. 2023 Jan 31;13(1):1716. doi: 10.1038/s41598-023-28674-1.

Authors

Dipesh Popli¹, Usha Batra², Velaphi Msomi³, Shubham Verma⁴

Affiliations

¹ GD, Goenka University, Gurugram, Haryana, India.
² Manav Rachna International Institute of Research and Studies (A Deemed to be University), Faridabad, Haryana, India.
³ Mechanical Engineering Department, Cape Peninsula University of Technology, Cape Town 7535, Western Cape, South Africa. msomiv@gmail.com.
⁴ MMEC, Maharishi Markendeshwar (Deemed to Be) University, Mullana, Haryana, India. shubham6140005@gmail.com.

Abstract

This research is focused on the drilling of Nickel based super alloy with diamond metal core drill and identified the significant parameters of rotary ultrasonic machining that optimise the machining rate (MR) and surface quality. Four general parameters: workpiece material, workpiece thickness, tool material, and tool size; and four RUM parameters: tool rotational, feed rate, ultrasonic power rating, and abrasive grit size of the tool were tested against and surface quality of the cut. The results indicated that the maximum value of MR of 0.8931mm³/sec is acquired at higher level of tool rotation, feed rate, ultrasonic power and moderate level of abrasive grit size of diamond. The minimum surface roughness (R_a) 0.554 µm is observed at higher level of rotational rotation, Moderate value of feed rate, ultrasonic power and diamond abrasive grit size. In addition, for single-objective and multi-objective functions, the particle swarm optimization (PSO) approach is used to find the optimum values for process parameters. Furthermore, a scanning electron microscope is also utilized to check the machined surface after RUM. It is concluded that microcracks are observed on the machined surface.