Surface quality evaluation in ultrasonic drilling through the Taguchi technique

Ultrasonic drilling of commercially pure titanium and titanium alloy (Ti-6Al-4v) was investigated in this study. During the experiments, process parameters such as work piece, grit size, slurry concentration, power rating and tools were changed to explore their effect on the surface roughness. Taguchi's technique was applied to obtain an optimal setting of ultrasonic drilling (USD) process parameters. Average surface roughness (Ra) was measured by using the Optical Profiling System. Two-dimensional and three-dimensional contour plots were obtained from the profiling system to quantify and visualize the surface roughness. From the experimental results and further analysis, it is concluded that the effect of slurry concentration and grit size have a significant effect on surface roughness more than other parameters. In addition, the surface roughness is apparently similar in two and three dimensions as visualized from contour plots. Ultrasonic drilling is established as a material removal process with good surface quality.