Modeling of ductile-mode material removal in rotary ultrasonic machining

In rotary ultrasonic machining of ceramic materials there exist two modes of material removal: brittle fracture mode and ductile mode. Two models were developed based on the assumption that the brittle fracture is the dominating mode of material removal, and were published previously. This paper presents the follow-up work on modeling of the ductile-mode material removal in rotary ultrasonic machining. After a brief review of the ductile phenomena in ceramic machining, an approach to modeling the ductile-mode removal in rotary ultrasonic machining is proposed. Then, magnesia stabilized zirconia is used to demonstrate the model's capability of predicting the material removal rate from the process parameters and the material property of the workpiece. Finally, the results of the pilot experiments to verify the model are discussed.