Tool Wear Analysis of USM for Composite Material using Taguchi Technique

In today's world, composite materials have many engineering application for manufacturing, packaging, automobile industry. For the machining of these composite materials, many accurate and cost effective machining processes have been used to reduce the machining time and man hour. The work piece of composite material of aluminium 6061 and silicon carbide powder of 100 mesh is prepared by the stir casting process with different weight fraction of powder in aluminium matrix. The prepared work piece of the composites are then carried out for machining on Ultra Sonic Machine to evaluate the tool wear rate with different process variables which are work piece material composition, amplitude, pressure and thickness of composite sheet. Experiments have been conducted to conclude that by changing the amplitude, tool wear is effectively increased at higher rate. Other variables also make definite changes which are smaller in comparison to amplitude. The comparison of mathematical model with experimental results will also serve as future validation of the model.