Sequential procedure for selecting the ranges of process parameters in rotary ultrasonic machining

Nickel-based alloys have numerous potential engineering applications. However, their widespread applications have been hindered by the elevated machining cost. There is a crucial need for commercial and cost effective machining processes for Ni-based super alloys. Rotary ultrasonic machining (RUM) is a hybrid machining process that combines the material removal mechanisms through diamond grinding and ultrasonic vibration (USM), resulting in higher machining rate than those obtained by conventional USM. Before going to the production run, it is necessary to conduct performance analysis followed by pilot experimentation for newer material. Relationships between desired outcome and the controllable machining parameters have been deducing. However, the relationships have been studied by screening the experiments. In this paper, a three-factor two-level factorial design followed by steepest ascent is utilised to find conditions for final experimentation. [Received 16 September 2016; Accepted 12 March 2017]