Grey Relational Analysis of Chemical Assisted USM of Polycarbonate Bullet Proof (UL-752) & Acrylic Heat Resistant (BS-476) Glass

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1 Ameican Jounal of Mechanical Engineeing, 017, Vol. 5, No., Available online at Science and Education Publishing DOI: /ajme-5--5 Gey Relational Analysis of Chemical Assisted USM of Polycabonate Bullet Poof (UL-75) & Acylic Heat Resistant (BS-476) Glass Kanwal Jeet Singh 1,*, Indepeet Singh Ahuja, Jatinde Kapoo 1 Depatment of Mechanical Engineeing, Giani Zail Singh Campus College of Engineeing & Technology, Bathinda, Punjab, India Depatment of Mechanical Engineeing, Univesity College of Engineeing, Punjabi Univesity, Patiala, Punjab, India Depatment of Poduction Engineeing, Guu Nanak Dev Engineeing College, Ludhiana, Punjab, India *Coesponding autho: khalsa.kanwal@yahoo.com Abstact This pape is developed an innovative pocess of chemical assisted ultasonic machining of polycabonate bullet poof UL-75 and acylic heat esistant BG-476 glass and conduct an investigation fo optimize the machining paametes associated with multiple pefomance chaacteistics using Gey elational analysis. Machining of polycabonate bullet poof UL-75 and acylic heat esistant BS-476 glass ae difficult pocess via conventional machining, howeve, it can be easily machined by Ultasonic machining. Caefully selected paametes gives the optimum esults. In this expeimental wok input paametes abasive sluy concentation, type of abasive, powe ate, git size of abasive paticles, hydo-fluoide acid concentation and tool mateial ae selected. The effect of input paametes viz mateial emoval ate, tool wea ate and suface oughness ae investigate. Gey elational analysis and analysis of vaiance ae pefomed to optimize the input paametes and bette output esults. In PBPG UL-75, incement in mateial emoval ate by 75.58%, tool wea ate by 45.4% and suface oughness by 4.18%. In othe hand, in AHRG BS-476, incement in mateial emoval ate by 61.4%, tool wea ate by 1.46% and suface oughness by.85%. The suface topogaphy is investigate though SEM images. It also obseved that HF acid have the significant ole in suface oughness. It also educe the mico cacks on machined zone. Hade tool and hade abasive slutty gives the highe mateial emoval ate, but it also enhance the tool wea ate. Keywods: USM, polycabonate, acylic, bullet poof, heat esistant, glass, HF acid, gey elational analysis Cite This Aticle: Kanwal Jeet Singh, Indepeet Singh Ahuja, and Jatinde Kapoo, Gey Relational Analysis of Chemical Assisted USM of Polycabonate Bullet Poof (UL-75) & Acylic Heat Resistant (BS-476) Glass. Ameican Jounal of Mechanical Engineeing, vol. 5, no. (017): doi: /ajme Intoduction Ultasonic machining (USM) is geneally pefeed fo amophous, had and bittle mateials. Glass, ceamics, titanium, titanium alloys and many moe mateials ae easily machined with USM [1,,]. If the hadness of mateial is moe than 40 HRC then USM is effectively pefomed. Mico holes as small as 76 µm diamete can be easily dilled by USM. The atio of depth to diamete is limited to :1. Duing USM neithe chemical no themal changes occu [5]. Moeove, no any metallugical vaiations aise on wok suface [4]. The histoy of USM stated since 197 with a eseach pape epoted by A.L. Loomis and R.W. Wood [8]. Ameican enginee Lewis Balamuth in 1945 was ganted fist patent [9]. USM pocess have been classified as ultasonic dilling, ultasonic cutting, ultasonic abasive and ultasonic dimensional machining [10,0]. In ealy 1950 s ultasonic ginding was modified into ultasonic impact machining. It was significant machining pocess and capable to machine toughest mateials [11]. In USM pocess, powe supply have an impotant ole. It convet low fequency electical signals into high fequency electical signals [11,1]. Afte that these signals ae tansmitted to tansduce. Two type of tansduce ae geneally used, magnetostatic and piezoelectic tansduce [14,1]. The tansduce convets high fequency electical signals into mechanical vibations. Though hon, the effect of vibations ae amplified and concentate on tool assembly. USM tool vibates along its longitudinal axis with ultasonic fequency between 0 khz to 40 khz [,14,15]. The amplitude of vibations ae measued in few hundedth of millimetes along longitudinal axis of tool. Hon and tool must be designed with mass and shape consideations, so that the esonance effect can be achieved with in the fequency ange [15,16]. Powe ating of USM vaies in between 50 W to 4000 W. Along longitudinal axis contolled static load is applied on the USM tool. Mixtue of abasive and caie medium is known as sluy. The concentation of sluy vaies fom 0% to 50% by volume [17,9]. It is pumped in between the gap of tool and wok suface. The optimum pumping speed of sluy is 0 litte/ min [15,18]. Wate is commonly used as a

2 95 Ameican Jounal of Mechanical Engineeing caie medium [1,15,18,19]. Because, it have low viscosity, low density, high themal conductivity and high specific heat chaacteistics [5,18,0,8]. Most pefeable abasives ae boon cabide, alumina, silicon cabide and diamond dust [1]. Abasive paticles ae foced by tool vibations to stike on wok suface. The impact of abasive paticles suppots to eode the mateial in the fom of mico-chips [,7]. The shape of cavity is simila to the USM tool []. Volumetic mateial emoval ate of USM is elatively low. Figue 1 shows the schematic diagam of simple USM [4]. The new appoach of USM is CNC contolled path otay USM [1,19,0,6]. SONEX00 extude hon made in Fance, EROSONIC US400 and EROSONIC US800 manufactued by Sonic Mill and made in USA ae commonly used on commecial level [5]. The USM machine is available in small tabletop sized units. The diffeent type of accessoies ae used fo suitability of opeation. Appopiate type of USM is detemined though capacity of powe ating [,7,10,,]. Figue shows the 500 W USM machine manufactued by Sonic Mill and made in USA, which is used fo small opeation [7,1,4]. The hon tansfe mechanical vibation enegy fom tansduce to tool. It also amplify the mechanical vibation effect. The hon mateial must have high fatigue, toughness and elastic popeties [1,1,5-40]. Geneally pefeed mateial fo hon ae silve steel, monal and tungsten cabide [,17,41-46]. Coppe washe is intoduced in between the tansduce-hon and hon-tool fastening, to pevent unnecessay ultasonic welding [8,1,47,48]. Figue Shows the cause and effect chat of USM and CUSM fo glass mateial. Figue 1. Schematic diagam of simple USM Figue. 500 W USM machine manufactued by Sonic Mill and made in USA

3 Ameican Jounal of Mechanical Engineeing 96. Mechanism of Mateial Removal in USM & CUSM.1. Taditional Ultasonic Machining Figue. Cause & effect chat of USM and CUSM fo glass mateial chaacteized by the aveage git diamete d g [6,64,65]. It is futhe assumed that the local spheical bulges have a unifom diamete, d b and which is elated to the git diamete by d b = µ d g. Thus an abasive is chaacteized by μ and d g. Mateial emoval pimaily occus due to the indentation of the had abasive gits on the bittle wok mateial. As the tool vibates, it leads to indentation of the abasive gits [16,49]. Duing indentation, due to Hetzian contact stesses, cacks would develop just below the contact site, then as indentation pogesses the cacks would popagate due to incease in stess and ultimately lead to bittle factue of the wok mateial unde each individual inteaction site between the abasive gits and the wok-piece [50,51]. The tool mateial should be such that indentation by the abasive gits does not lead to bittle failue. Thus the tools ae made of tough, stong and ductile mateials like steel, stainless steel and othe ductile metallic alloys [5]. Othe than this bittle failue of the wok mateial due to indentation some mateial emoval may occu due to fee flowing impact of the abasives against the wok mateial and elated solid-solid impact eosion, but it is estimated to be athe insignificant [5-60]. Thus, in the cuent model, mateial emoval would be assumed to take place only due to impact of abasives between tool and wokpiece, followed by indentation and bittle factue of the wokpiece. The model does conside the defomation of the tool. In the cuent model, all the abasives ae consideed to be identical in shape and size [61,6]. An abasive paticle is consideed to be spheical but with local spheical bulges as shown in Figue 4. The abasive paticles ae Figue 4. Schematic epesentation of abasive git Duing indentation by the abasive git onto the wokpiece and the tool, the local spheical bulges contact the sufaces and the indentation pocess is chaacteized by d b athe than by d g [66,67]. Figue 5 shows the inteaction between the abasive git and the wok-piece and tool. As the indentation poceeds, the contact zone between the abasive git and wok-piece is established and the same gows [68,69,70]. The contact zone is cicula in natue and is chaacteized by its diamete x. At full indentation, the indentation depth in the wok mateial is chaacteized by δ w. Due to the indentation, as the wok mateial is bittle, bittle factue takes place leading to hemi-spheical factue of diamete x unde the contact zone. Theefoe mateial emoval pe abasive git is given as.

4 97 Ameican Jounal of Mechanical Engineeing As the indentation poceeds, the contact zone between the abasive git and wok-piece is established and the same gows [71,7]. The contact zone is cicula in natue and is chaacteized by its diamete x. At full indentation, the indentation depth in the wok mateial is chaacteized by δ w. Due to the indentation, as the wok mateial is bittle, bittle factue takes place leading to hemi-spheical factue of diamete x unde the contact zone. Theefoe mateial emoval pe abasive git is given as equation 1 and Now Fom Figue 4 AB = AC +BC Figue 5. Inteaction between git and wok-piece and tool Γ w = π X. (1) db db = δ x + X δ τ Tδ T ( δw + δt = τ = =. a T /4 4a 4a = bδw. δw δw << b X d Negecting as d w π ( d ) bδw. Γ = () If at any moment of time, thee ae an aveage n of gits and the tool is vibating at a fequency f then mateial emoval ate can be expessed as equation MRR w = Γ w.. n f MRR ( ) w π dbδw.. n f. = () Now as the tool and wokpiece would be pessing against each othe, contact being established via the abasive git, both of them would defom o wea out. As the tool vibates, fo some time, it vibates feely; then it comes in contact with the abasive, which is aleady in contact with the job, and then the indentation pocess stats and finally completes with an indentation of δ w and δ t on the wok and tool espectively. Figue 6 schematically depicts the same assuming the wok to be igid fo easy depiction. The tool vibates in a hamonic motion [7]. Thus only duing its fist quate of its cycle it can deive an abasive towads inteaction with the tool and wok-piece as shown in Figue 7 Out of this quate cycle, some pat is used to engage the tool with abasive paticle as shown in Figue 6. [74] Thus the time of indentation τ can be oughly estimated as Figue 6. Inteaction between git and wok-piece and tool to depict the wok-piece and tool defomations Now duing machining, the impulse of foce on the tool and wok would be balanced. Thus total impulse on the tool can be expessed as equation 4 1 lt nf.. Fmaxτ = (4) Whee F max is the maximum indentation foce pe abasive. Now in the USM, the tool is fed with an aveage foce F 1 F Fmaxτ.. nf. = (5) Again, if the flow stength of wok mateial is taken as σ w, then foce is equation 6 F max = σ πx w 1 F = σ.. w πx τ nf T ( δ + δ ) 1.. w t = σwπ. (6) 4a0 F nf X If A is total suface aea of the tool facing the wok-piece, then volume of abasive sluy of one git thickness is Ad g.

5 Ameican Jounal of Mechanical Engineeing 98 If n is the numbe of gits then the total volume of n gits is π d g n 6 Thus the concentation of abasive gits in the sluy is elated as follows shown in equation 7. π d g n = 6 π dg n C = 6 = Adg Figue 7. Change in tool position due to ultasonic vibation of the tool Ad C g dg n 6A π 6AC n = n. (7) π dg Now it is expected that indentation would be invesely popotional to the flow stength then, δt σw = = λ. δ σ w Again combining, F can be witten as equation 8 1 F X nf t T = σwπ τ.. δw(1 + λ) (8) 4a0 16AC T F = f. σ (1 ) wπdbδw δw + λ π d 4a g 0 σ AC w F = ( ft. ) d (1 ) b δ w + λ d 4a g 0 σ µ δ λ AC w F = ( ft. ) d (1 ) g w + d 4a g 0 δ 4aF 0 w = AC w µ σ (1 + λ) 6cA MRRw =Γ w.. nf= πx nf. = π. fx. π dg ca 4cA = 4 π. f.( d )..(. ) wδ w = f µ d gδw π dg dg = 4 cad g µ. f. 4Fa 0 { } µ Acσw (1 + λ) c A F a d MRR 0 g f α µ 4 σ 4(1 ) 4 w + λ c A ρ a. d g f σ 4(1 ) 4 w + λ α µ (9) (10) Mechanism of mateial emoval o eosion is investigated by vaious eseache [8,9,8,74,75]. Figue 8 shows basic mechanism of mateial emoval pocess in USM. Fo bittle and had mateial, factue effect poduced the eosion. Similaly, sheaing effect is utilized fo ductile mateials. Eosion effect is poduced though bombadment of abasive paticles diectly against the wok suface [76,78,79]. Appopiate flow of sluy will enhanced the mateial emoval ate [80]. Cavitation effect is also fomed by sluy, which educe the mateial emoval ate. Mateial is emoved in the fom of micochips and flush out with sluy [0,,46,65]. Figue 8. Basic mechanism of mateial emoval pocess in simple USM Figue 9. Basic mechanism of mateial emoval pocess in chemical

6 99 Ameican Jounal of Mechanical Engineeing.. Chemical-assisted Ultasonic Machining In chemical-assisted ultasonic machining (CUSM), low concentation of hydofluoic acid (HF) is used in sluy. HF acid eaction between Si and F - ions and O and H + occu simultaneously. When HF acid eact with glass then the bonding foces between Si molecules on the suface aea become weakened. This mechanism impove the efficiency of USM [7,11,1,1,14,1]. Figue 9 shows Basic mechanism of mateial emoval pocess in chemical.. Type of Glass and Application Glass is non-cystalline o amophous mateial. It is tanspaent by appeaance and used in many appliances such as window panels, optoelectonics, technological equipment, optical etc. [65,66,67]. The main ingedient of glass is silica (sand) [68]. Many silica based glasses ae exist such as containe glass and odinay glass, which ae manufactued by specific type of soda-lime glass. The main composition of soda-lime glass is appoximately 75% SiO (silicon dioxide), Na CO (sodium cabonate), Na O (Sodium oxide), CaO (calcium oxide o lime) and some mino othe additives [67,68,69]. Window panels ae geneally manufactued by silicate glasses. Glass eflect as well as tansfe light fom own self. These eflection and tansfomation quality is utilized to make pisms, optical fibe, lenses and fine glasses. Optical fibe ae used fo high speed data tansmission. The colo of the glass is changed by adding some ingedient like metallic salt, zinc etc. [68,70,71]. These type of coloed glass is used in manufactuing the at object, stained glass window, colo glass window and many moe applications. Glass is easily fomed o molded into any equied shape, so it is taditionally used in the manufactuing of bowls, jas, vases, bottles and dinking jas. The most had and solid fom of simple silicate glass used fo mables, beads and papeweights [71,7,74,75]. The othe moden example of the glass is glass fibe, the glass is extude unde the high tempeatue and conveted into the fibe glass o glass wool. Glass fibe have popety of data tansfeed at the speed of light. Glass wool is used as the themal insulating mateial [7,76,77,78,79]. The othe application of glass fibe, it is used as the einfocement mateial in the composite mateial fibe glass. Many themoplastic and pocelains mateial ae the close familia to the glasses. The addition of these close familia mateial impove the popeties of the silicate glass. Acylic glass, polyethylene, teephthalate and polycabonate these ae the lighte altenative of the simple silicate glasses [67,71,77,79]..1. Polycabonate Bullet Poof & Acylic Heat Resistant Glass Polycabonate bullet poof glass, acylic heat esistant glass and glass-clad polycabonate bullet poof glass ae the advanced types of glass [78]. These glasses ae manufactued by affixing two diffeent mateials though epoxy esin liquid [59]. In polycabonate bullet poof glass, layes of glass and polycabonate mateials ae affixed with each othe. Numbe of layes ae defined accoding to the bae load [85]. Elastic effect is poduced by polycabonate mateial duing impact load [78]. Thickness of polycabonate bullet poof glass is vaies fom 10 mm to 76 mm [75]. Similaly in acylic heat esistant glass, layes of glass and acylic mateial ae affixed with each othe though epoxy esin [56]. Acylic glass is also known as poly (methyl methacylate) o PMMA mateial. It is a tanspaent themoplastic often used in sheet fom as a lightweight, shatte esistant and heat esistant mateial [71]. Acylic (PMMA) mateial of mm thick sheet can tansmits up to 9% of visible light. It have poo themal conductivity [7,76]. Thickness of acylic heat esistant glass is vaies fom 85 mm to 150 mm. Table 1 shows thickness and density of advanced glass mateial [45]. Potection level Table 1. Thickness and density of advanced glass mateial Theat Stopped Polycabonate Glass Acylic Glass Glass Clad PC Glass shot Thickness Density Thickness Density Thickness Density inch Kg/m inch Kg/m inch Kg/m UL 75 level I 9mm UL 75 Level II.6 Magnum UL 75 Level III.45 Magnum UL 75 Level IV.0 Calibe 1 shot Figue 10. Plain Glass unde impacted by bullet Figue 11. Polycabonate bullet poof glass impacted by bullet

7 Ameican Jounal of Mechanical Engineeing 100 Table. Impotant popeties of polycabonate bullet poof and acylic heat esistant glass Popeties PBPG (UL-75) AHRG (BS-476) Physical Popeties Density 7 gm/cm 8. g/cm Refactive Index Flammability V 0 -V V 0 -V 4 Limiting Oxygen Index 5-7% 1-4% Wate Absoption % % Radiation Resistant Fai Fai Mechanical Popeties Young s Modulus.0-.4 GPa GPa Tensile stength (Depend on thickness) MPa MPa Compessive Stength 1000 MPa ( at 7 o F) 100 MPa (at 7 o F) Linea expansion (0 to 00 o C) 9x10-6 m/(m-k) 8. x10-6 m/(m-k) Themal Conductivity at o C 0.0 W/(m-K) 0.86 W/(m-K) Reactivity with HF Acid poo poo Hadness 58 HRC 61 HRC Themal Popeties Glass Tansition Tempeatue 147 o C 158 o C Themal Conductivity at o C W/(m-K) W/(m-K) Themal Diffusivity at o C mm /s 0.04 mm /s Linea Themal Expansion Coefficient 65-70x10-6 /K 4-58 x10-6 /K Chemical Resistance Popeties Acids (Concentated), Halogens, Ketones and Aomatic Hydocabons Poo Poo Acid (Dilute) and Alcohols Good Good Geases, Oils and Halogenated Fai Poo Glass have poo elasticity popety, mean it can t defomed when foce applied on it [7]. Figue 10 shows plain glass unde impacted by bullet [71]. In which impact load of bullet beak the plain glass. Figue 11 shows polycabonate bullet poof glass. Fist laye of glass may shatte when the bullet hits it, howeve the next laye of polycabonate is moe elastic so it moves when the bullet stike. Impact enegy of bullet is dissipates vetically [56,69]. This takes the enegy away fom the bullet and it slowing down. If the enough enegy is taken fom the bullet, it will eventually stop it fom passing though [69]. Some impotant popeties of these mateial make them so famous and the utility of these mateials ae inceased in pesent ea [69,70,71]. Table shows some impotant popeties of polycabonate bullet poof glass and acylic heat esistant glass [54,55,76]. Figue 1 shows the acylic heat esistant glass. 4. Expeimentation and Data Collection The expeiments wee pefomed on 500 W USM machine manufactued by Sonic mill and made in USA, which is used fo small opeation. The diffeent components of USM machine and enlaged view of cutting zone ae shown in Figue 1. Input paametes and fixed paametes fo investigation ae shown in Table 4. MRR was calculated by measuing the weight loss afte dilling thoughout the wok mateial. Similaly, TWR computed by weight loss duing each expeiment. Time duation of expeiment was ecod by stop watch. MRR TWR W W ρ Xt i f = 1000( mm / min). (11) T T ρ Xt i f = 1000( mm / min). (1) Suface oughness is measued is R a, it is the univesally ecognised and most used intenational paamete of oughness. It is the aithmetic mean of the absolute depatue of the oughness pofile fom the mean line. Afte machining the MRR and TWR ae calculated and SR is checked, machining data is shown in Table 5. In which MMR and TWR is calculated in mm /min and suface oughness in R a. 5. Gey Relational Analysis Figue 1. Basic fundamental of heat esistant In gey elation analysis, data pe-pocessing is necessay to sequence scatte ange. In data pe-pocessing oiginal sequence is tansfeed into compaable sequence.

8 101 Ameican Jounal of Mechanical Engineeing The expeiment esults ae nomalized in the ange 0 and 1. Depending on output paametes, data pe-pocessing methodologies ae adopted [5,9]. Fo example, MRR is the govening output paamete in USM, which decided the machinability of wok mateial unde delibeation. Lage-the-bette chaacteistics was used fo MRR to nomalize the oiginal sequence by equation 1. * Y ( ) ( ) ( ) N MinY N Y N = MaxY ( N) MinY ( N) (1) Whee, Y * (N) is the sequence afte the data pocessing, Y (N) is the compaability sequence, N=1 and N=4 fo MRR; = 1,, 7 fo expeiment numbe 1 to 7. TWR and SR ae the impotant measue of USM, these output paametes ae epesent the machining accuacy unde selected input paametes [,8]. To get the optimum pefomance the Smalle-the-bette chaacteistic has been pefeed to nomalize the oiginal sequence date by equation 14. * MaxY ( ) ( ) ( ) N Y N Y N = MaxY ( N) MinY ( N) (14) Whee, Y * (N) is the sequence afte the data pocessing, Y (N) is the compaability sequence, N=, N=5 fo TWR and N=, N=6 fo SR; i= 1,, 7 fo expeiment numbe 1 to 7. Y * (N) is the value afte gey elational geneation, Min Y (N) and Max Y (N) ae the smallest and lagest value of Y (N). Afte nomalized MRR, TWR and SR of PBPG UL-75 and AHRG BS-476 compaable sequence is shown in the Table 6. S. No Autho (s) K.Singh et al. 016 [5] K.Singh et al. 015 [51] J.Kuma & J.S Khamba 009 [66] J.P. Choi et al. 007 [1] P.L. Guzzo et al. 00 [17] M. Komaaiah & P. Naasimha 199 [18] M. Komaaiah et al [] M. Adithan & V.C. Venkatesh 1976 [57] M. Adithan 1974 [7] A.Schodeet et at 01 [67] Wok mateial Glass Glass Cabide glass, HCS, HSS, Al and Ti Glass Soda lime glass, Alumina, Ziconia, LiF Quatz & Feite Glass Glass, Feite, Pocelain, alumina and cabide Glass Glass & pocelain Glass Table. Summay of selected eseach papes on USM of glass mateial Output factos & Input factos Results o conclusion Optimized Results Abasive (Al O, SiC, Mixtue) Powe ating 60 MRR = 1 mm CUSM gives moe MRR as compae to /min, Git 80 TWR = 1.0 mm USM. Bette SR is achieved in CUSM. /min, High concentation of HF acid incease Concentation 0% SR = 1.0 micon the TWR. HF acid % Abasive (Al O, SiC, Mixtue) Powe ating 40 Git 400 Concentation 0% HF acid % Wok mateial (HCS, HSS, Al, Titanium, Cabide, Glass) Tool mateial (HCS, Titanium, Titanium alloy) Abasive (Al O, SiC, B 4 C) Git size (0, 0, 500) Tool geomety (Solid 8mm, Solid 4mm, Hollow 8/4) Abasive = SiC Static load = 0.1 gf HF acid = -5%, git, Thickness of mateial (0.5 to 1.75 mm) Git size (6,15,5,5 & 50 µm) Abasive (Al O SiC, B 4 C) Tool mateial & tool motion (stationay & otay) Wok mateial and tool mateial Tool mateal = mild steel, silve steel, tungsten cabide & Stainless steel Abasive = SiC & B 4 C Git Size = 80 & 600 Static load Wok mateial = glass & pocelain Thickness of mateial = 0.50 to.5 mm Tool mateial = Mild stel, Silve steel, stainless steel & tungsten cabide Abasive = Al O, SiC & B 4 C Git Size = 80 &600 Abasive = B 4 C Concentation 10% Git size = 5µm Tool Mateial = WC, HSS SR = 0.98 micon, MRR = 8 mm /min, MRR = 1.07 mm /min, TWR = 1.9 mm /min, MRR inceased 00%, SR impoved 40%, MRR =.4 µm/s SR = 1. micon MRR = 1. log MRR (mm /min) TWR = 0.6 log TWR (mm /min) MRR = mm /min SR = 1.8 Micon Out of oundness =0.085 mm TWR = 0.84 mm /min Out of oundness =0.09 mm MRR = 1.54 mm /min TWR = 0. mm /min MRR (WC) = mm /min TWR (WC) = 5. µm/s HF acid in Alumina, SiC and Alumina + SiC abasive impove the SR.86%,.84% & 55.4%, Similaly Impove MRR 1.85%, 40.8% & 64.08% espectively. Fo tool wea, tool geomety 5.7%, git size 0.1% & abasive 19.95% wee the significant facto. Fo mateial emoval; wok mateial 79%, tool geomety 10.86% and git size 5.50% significant facto. Fo TWR; wok mateial was most significant facto. HF acid impove the MRR upto 00%, CUSM gives bette SR as compae to USM and static load deceased damatically. MRR is invesely popotional to depth of cut in alumina, zicona and quatz mateial, in othe mateial it may be constant. MRR & SR dependent on H/E atio. Deceasing ode of tool pefomance accoding to TWR; nimonic-80 A > thoiated tungsten > slive steel > maaging steel > stainless steel > titanium > mild steel. Highe MRR gives high TWR. Highe H/E atio mateial gives highe MRR & highe out-of oundness. RUSM gives bette esults as compae to simple USM. Ovesize of hole & conicity effects ae inceased with highe static load and machining time. It also depends upon the bittle factue chaacteistics and gain stuctue of wok mateial. Tool wea ate incease with incease in static load. B 4 C abasive gives moe TWR as compae to Al O & SiC Twisted gouges dill gives bette esult as compae to plain dill. High flow ate emove the debis at machining zone.

9 Ameican Jounal of Mechanical Engineeing 10 Facto (Symbols) Figue 1. Diffeent components of USM and enlaged view of cutting zone Table 4. Input paametes and output paametes fo investigation Input Paametes Levels Level 1 Level Level Concentation (A) 0% 0% 40% Abasive (B) Al O +B 4 C (1:1) SiC+ B 4 C (1:1) Al O + SiC+ B 4 C (1:1:1) Powe Rate (C) 0% 40% 60% Git Size (D) HF Acid (E) 0.5% 1% 1.5% Tool Mateial (F) D High-Cabon Steel High-Speed Tool Steel Table 5. Design of expeimentation (Othogonal Aay L7) and thei levels Polycabonate Bullet poof (UL-75) glass Acylic Heat Resistant (BS-476) Glass Tail MRR (mmmm /mmmmmm) TWR (mmmm /mmmmmm) (SR) Ra (Micon) MRR (mmmm /mmmmmm) TWR (mmmm /mmmmmm) (SR) Ra (Micon)

10 10 Ameican Jounal of Mechanical Engineeing Tail Refeence Sequence Table 6. The sequences of each pefomance chaacteistic afte data pocessing Polycabonate Bullet poof (UL-75) glass Acylic Heat Resistant (BS-476) Glass MRR TWR SR MRR TWR SR Table 7. The deviation sequences Deviation Sequence 0 (1) 0 () 0 () 0 (4) 0 (5) 0 (6)

11 Ameican Jounal of Mechanical Engineeing 104 Now 0 (N) is the deviation sequence between efeence sequence Y 0 (N) and the compaability sequence Y * (N) (Ahmad et al. 016) [81]. Deviation sequence is calculate and maximum and minimum diffeence is found, N=1, and and = 1,, 7 by equation 15 0( N) = Y0( N) Y( N) (15) The deviation sequence table is shown in the Table 6, Maximum ( Max ) and Minimum ( Min ) ae obtained and shown below. 10 ( ) 6 ( ) 0 ( ) ( 4) ( 5) ( 6) 1 6 ( ) 09 ( ) ( ) ( 4) ( 5) ( 6) 0. Max = 1 = = = 19 = 6 = 0 = Min = 1 = = = = = = Afte pe-pocessing data, the next step in calculate the Gey elational coefficient and Gey elation gade with the pe-pocessed data [8,47]. It define the elationship between ideal and actual nomalized esults. Gey elational coefficient ξ can be expessed by equation 16 [8]. Min + ρ Max ξi ( N) = (16) ( N) + ρ Max 0 Whee, 0 (N) is the deviation sequence of the efeence sequence Y 0 (N) and the compaability sequence, φ is distinguishing o identification coefficient. In this calculation φ=0.5, because all paametes ae given equal pefeence [4,59]. The Gey elation coefficient fo each expeiment of the L7 othogonal aay is calculated and shown in Table 8. Afte obtaining the Gey elation coefficient, the Gey elation gade γ is obtained by aveaging the Gey elation coefficient coesponding to each pefomance chaacteistic and epesent by ξ (1), ξ (), ξ (), ξ (4), ξ (5) and ξ (6) by equation 17, the geneal fomula of Gey elation gade and fo thee output paametes, shown in Table 8. 1 n γ = { ξ ( )} N 1 N (17) n = 1 γ = { ξ (1) + ξ () + ξ ()}. The highe value of Gey elation gade is epesent that the coesponding expeiment esult is much close to the ideally nomalized value. Expeiment numbe 5 get the best multiple pefomance chaacteistics among the 7 expeiment because it have the highest value of gey elation gade. Now the expeimental design is othogonal, it is possible to sepaate out the effect of each paametes on the basis of Gey elation gade. Mean of Gey elation gade is calculated fo level 1, and by aveaging the Gey elation gade of the expeiment 1to 9, 10 to18 and 19 to 7 ae shown in Table 9. The mean of Gey elation gade fo abasive, powe ate, git size, HF acid and tool mateial ae calculated in same manne. The total mean of Gey elation gade fo 7 expeiment is also shown in the Table 9. Level fo optimum gey elational gade. Optimum level paametes ae find out fom esponse table and shown in the Figue14. Lage value of Gey elation gade is close to the ideal value. Theefoe, the optimum paametes setting fo highe MRR and lowe TWR and SR ae A B C D E 1 F. Expt. No. Table 8. The calculated Gey Relational Gade and its ode in the optimization pocess Gey Relational Coefficient Gey Relation Gade { ξ i (1)} { ξ ()} { ξ ()} { ξ i (4)} { ξ i (5)} { ξ i (6)} i i 1 γ m= { ξi (1) + ξi () + ξi () 6 + ξi(4) + ξi(5) + ξi(6)} Rank

12 105 Ameican Jounal of Mechanical Engineeing Symbol Machining Paametes Table 9. Response Table fo the Gey Relational Gade Gey Relation Gade Level 1 Level Level Main Effect (Max- Min) A Concentation B Abasive C Powe Rate D Git Size E HF Acid F Tool Mateial Total men value of the Gey elational Gade γ m = Rank Gey Relational Gade Gaph (Gey Relational Gade Vs Level) 0.66 Concentation Abasive Powe Rate Git Size HF Acid Tool Mateial Gey Relational Gade AlO+BC SiC+BC AlO+SiC+BC % 1% 1.5% D HCS HSTS Figue 14. Effect of USM paametes on the multiple pefomance chaacteistics Table 10. ANOVA of Gey elation gade Paamete Degee of Feedom Sum of Squaes Mean Squaes F Ration Pecentage Contibution Concentation (A) % Abasive (B) % Powe Rate (C) % Git Size (D) % HF Acid (E) % Tool Mateial (F) % Eo % Total Futhemoe, analysis of vaiance (ANOVA) is pefomed on Gey elation gade to achieve contibution of each input paamete affecting the output paametes. ANOVA fo Gey elational gade is shown in Table 10. In addition, F-test is also used to find out the pecentage contibution of each paametes. Fom Table 10 it is clea that mateial of tool have the significant ole in the machining which have 0% contibution, 5% contibution of concentation, 1% contibution of git size, 9% contibution of abasive, 4% contibution of HF acid and % contibution of powe ate in the machining of PBPG UL-75 and AHRG BS-476. Afte getting the optimum paametes, the expeiment was pefomed by GRA input setting (A B C D E 1 F ). Figue 15 show the Scanning electon micoscope (SEM) images of PBPG UL-75 machining setting A 1 B 1 C 1 D 1 E 1 F 1, In which, some cack ae also found on the wok suface. In othe hand in Figue 16 the USM machining of PBPG UL-75 is pefomed by optimum paametes which ae found by Gey elational analysis A B C D E 1 F, thee is smoothe and cack fee suface. Similaly, in Figue 17 show the Scanning electon micoscope (SEM) images of AHRG BS-476 machining setting A 1 B 1 C 1 D 1 E 1 F 1, in which machining by USM is pefomed and some cack ae also found on the wok suface. In othe hand in Figue 18 the USM machining AHRG BS-476 is pefomed by optimum paametes which ae found by Gey elational analysis A B C D E 1 F, thee is smoothe and cack fee suface.

13 Ameican Jounal of Mechanical Engineeing 106 Figue 15. SEM image of PBPG UL-75 A 1 B 1 C 1 D 1 E 1 F 1 expeiment Figue 16. SEM image of PBPG UL-75 A B C D E 1 F optimum Gey elational analysis Figue 17. SEM image of AHRG BS-476A 1 B 1 C 1 D 1 E 1 F 1 expeiment Figue 18. SEM image of AHRG BS-476A B C D E 1 F optimum Gey elational analysis

14 107 Ameican Jounal of Mechanical Engineeing Figue 19. Pecentage contibution of facto on Gey Relational Gade Table 11. Impovement in Gey elational gade with optimized USM machining paametes Optimal Machining Paametes Condition Desciption Machining Paametes in Fist tail of OA Gey Theoy Pediction Design PBPG UL-75 Gey Theoy Pediction Design AHRG BS-476 Level A 1 B 1 C 1 D 1 E 1 F 1 A B C D E 1 F A B C D E 1 F MRR (mm /min) TWR (mm /min) SR (micon) Gey Relational Gade ` Impovement in Gey elational gade = MRR and TWR ae also compaed between optimum Gey elational analysis A B C D E 1 F and A 1 B 1 C 1 D 1 E 1 F 1 input paametes. It obseved that optimum paametes (A B C D E 1 F ) gives 7.0% impoved MRR with compaison of A 1 B 1 C 1 D 1 E 1 F 1 USM expeiment setting. TWR is deceased by 7.5%. It is evident fom SEM image, optimum paametes setting also give the bette suface oughness which is 4.% impoved. Fig 19 shown the pecentage contibution of optimum Gey elational analysis paametes. Confimation test is caied out to veify the impovement of pefomance chaacteistics in machining of PBPG UL-75 and AHRG BS-476 by USM. The optimum paametes ae shown in the Table 11. The estimated Gey elational gade ˆ γ using the optimal level of machining paametes can be calculated by equation 18 [15,19,4,59] ˆ n γ = γm + i 1 { γi γ = m } (18) Whee, γ m is the total mean of Gey elational gade, γi is mean of the Gey elational gade at optimum level and n is the numbe of paametes that significantly affect multiple-pefomance chaacteistics. It is clealy show that the multiple-pefomance chaacteistics in USM pocess is geatly impoved though this study. 6. Conclusion The optimum machining paametes ae identify by Gey elational gade fo multiple pefomance chaacteistics that is MRR, TWR and SR. This expeimental eseach pape pesented the multi-objective optimization of USM machining paametes of polycabonate bullet poof UL-75 and acylic heat esistant BS-476 glass fo dilling application by Gey elational analysis method. Following conclusion ae conclude fom the expeimentation analysis. 1. It conclude that, hade mateial like HSS gives the bette mateial emoval ate and lowe tool wea ate. In USM, concentation of abasive sluy, concentation and git size of abasive play the significant ole fo optimum output pefomance paametes.. Hade abasive paticles incease the mateial emoval ate, but it also enhanced the tool ea ate.. HF acid have the significant ole play in the mateial emoval ate as well as suface oughness. High concentation of HF acid will damage the wok piece as well USM appaatus. It is also ham full fo the opeato. 4. Though mathematically modelling it conclude that shape of abasive paticles have the majo ole in mateial emoval and tool wea ate. MRR affect is futhe encouage by the concentation of sluy. 5. Highe concentation of abasive sluy gives highe mateial emoval ate, but it decease the flow ate of sluy. 6. ANOVA of Gey elational gade fo multiple pefomance chaacteistics eveals that the concentation have the significant ole in the MRR. 7. Based on SEM images, it is evident that optimum paamete impove the suface oughness and give bette smooth suface and it also educe the cacks fomation.

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