Chemical assisted ultrasonic machining of polycarbonate glass and optimization of process parameters by Taguchi and grey relational analysis

Abstract

Polycarbonate bullet proof (UL-752) glass is highly demanded material in automobile, aerospace and space industries. It is also used in security chambers or buildings, because of its unique properties such as; impact bare capacity, hardness, excellent transparency, higher mechanical strength, good dimensional stability etc. Objective of this research investigation is focused at studying the impact of different input parameters (concentration, abrasive, power rating, grit size, HF acid concentration and tool material) on output responses (material removal rate, tool wear rate and surface roughness) in ultrasonic drilling of polycarbonate bullet proof (UL-752) glass. The experiments have been performed by using Taguchi’s L₂₇ orthogonal array and grey relation analysis has been used for the optimization of multiple responses. To find out the significant factors, analysis of variance is further employed. Through GRA approach, MRR and TWR improved by 113% and 100% respectively. HF acid also reduced the delamination affect.

Keywords:

• Ultrasonic
• polycarbonate
• glass
• grey relational
• HF-acid
• chemical- assisted

Abbreviation:

• CUSM: Chemical assisted ultrasonic machining
• PBPG: Polycarbonate bullet proof glass
• HF: Hydrofluoric
• MRR: Material removal rate
• TWR: Tool wear rate
• SR: Surface roughness
• DOE: Design of experiment
• DOF: Degree of freedom
• OA: Orthogonal array
• GRA: Grey relation analysis
• GRC: Grey relation coefficient
• GRG: Grey relation grade
• F: Fisher’s test
• S/N: Signal to noise ratio
• ANOVA: Analysis of variance
• SEM: Scanning electron microscope