MRR in USM

Model proposed by M.C.Shaw.

Assumptions made:
1. Abrasive particles are spherical in shape

2. Tool & abrasives are rigid.

3. metal removal is based on hemisphere fracture mechanism

4. MRR is based on the brittle fratcture of the work material.

5. Volume of particle removed is approximately proportional to

the diameter of indentation (2r).
 Let ,
 Depth- h
 Radius of

indentation- r d
 Frequency- f
 Radius of
R
R-h
abrasive- R r h
 Volume of material removed due to fracture
per grit per cycle
Vg = 2/3(πr3) r2= (d/2)2 –(d/2-h)2
= 2/3 π(dh)3/2 ≈ dh
Vg = K1(dh) 3/2 K1 =constant

N-number of impacts on w/p

N= K2(1/d2) K2 =constant of proportionality
K3 =probability of effective abrasive particle.
Volume removed= f x (amt of mat’l removed /cycle)
= K1K2K3f √(d3h3/d4).
V= Vc.f = K1K2K3f √(h3/d).
  To evaluate depth of penetration M.C.Shaw
proposed two models
1. Throwing
2. hammering

ht

hw

d h= ht+hw

R
R-h
r h
 Model 1 (Grain throwing)
 Particle is hit & thrown by tool onto w/p.
 Displacement- Y

 Amplitude- a/2 and 2πf=ω

 Time- t

Y = a/2 sin(2πft)
Velocity = Y˚ = πaf cos(2πft)
Y˚ max = πaf for max… cos(2πft)=1
Kinetic energy K.E =½ mv2= ½ m π2a2f2
= ½ (πd3ρ/6) π2a2f2 .... m= (πd3ρ/6)
Work done = force x depth of penetration
= Fhth/2
Work done = K.E
Fhth/2 = ½ (πd3ρ/6) π2a2f2
hth= (π3ρa2f2d3)/(6F)
Mean stress on w/p σw =F/A = F/(πdhth)
F= σwπd hth
Now,
hth= (π3ρa2f2d3)/(6 σwπd hth)
hth = πafd √(ρ/(6 σw))
Now, volumetric material removal rate
V= K1K2K3f √(h3/d)…………. General equation.

Vth= K1K2K3 {(π2a2ρ)/(6σw)}3/4 .df 5/2

Model 2 (Grain hammering)
 When the gap b/w tool & w/p is smaller than
the dia of grit it will result into partial
penetration in the tool, & also in w/p.
 h ,h will depend on the hardness of the tool
tl w
& w/p.
 Force F acts on the abrasive particle only for

the short time (△T) during the cycle time T.

 The mean force

 F = 1/T ʃF(t) dt
avg
 The force starts increasing as soon the grit gets
in contact with tool & w/p at same time .
 It attains max and then starts decreasing, hence

the momentum equation is given by

ʃF(t) dt= (F/2)△T
mean velocity = (a/2)/(T/4) amplitude=a/2
△T= hh.(T/4)/(a/2)
= hhT/(2a)
Favg=hh/4aF……. F= Favg4a/hh
N-no of effective grains under tool
stress σw= F/(Nπd hw)
σtl= F/(Nπd htl) = σw hw/htl
σw= Favg(4ad2)/(K2hhπd hw) hh =htl+hw
= 4Favgad
K2πdhw2(htl /hw+1)

htl /hw=σtl/σw =j

hw=√ 4Favgad
K2π σw(j+1)
Volumetric material removal rate

Vh = K1K2K3 4Favga 3/4

.d f
K2π σw(j+1)
HORN DESIGN
 LET
F- force
σx- stress
A- shape function or c/s area fn of horn in axial
position, is a fn of ‘x’.
y- displacement y=u sin ωt
u- oscillation amplitude
∂y/∂x- strain
ω = 2πf
F= EA ∂y/∂x---------------F=E σℇ
 Elastic force
 =(σ +∂σ /∂xdx)(A+ ∂A/∂xdx)-σ …..∑F
x x x dx

= A∂σx/∂xdx+ σx∂A/∂xdx
Inertia force= Adx.ρ(∂2u/∂t2) ……F=ma
Equating elastic & inertia fores
A∂σx/∂xdx+ σx∂A/∂xdx = Adx.ρ(∂2u/∂t2)
Now u=asin ωt+bcos ωt
so, ∂2u/∂t2= -ω 2u

A∂σx/∂x+ σx∂A/∂x=ρA(-ω 2u)

We have, σx=E∂u/∂x
AE (∂2u/∂x2) +E (∂u/∂x)(∂A/∂x)=- ρAω 2u
 AE (∂2u/∂x2) +E (∂u/∂x)(∂A/∂x)=- ρAω 2u
 Dividing by AE we get,

(∂2u/∂x2)+(∂u/∂x)(∂A/∂x)/A+(ω 2/c2)u=0

where c2= E/ρ -velocity of sound in material

Cylindrical stepped horn
 A= constant C
A=C
So, general equation becomes
(∂2u/∂x2)+(ω 2/c2)u=0

Magnification factor
Rm=ℇl/ℇ0 =(Dl/D0)2

Used for brittle materials ( glass, Ge, Ceramics)

 Exponential horn
 A= A0 e(-2hx)
 D= D0e(-hx) …h=exponential ascent factor
 (∂2u/∂x2)+(∂u/∂x)(∂(A e(-2hx))/∂x)/(A e(-2hx))+(ω 2/c2)u=0
0 0

A
 (∂2u/∂x2)-2h(∂u/∂x)+(ω 2/c2)u=0
 Length
L= π/(√{(ω 2/c2)-h2})
but, h =(ω /c)/(√{1+(π/hl)2})
l= c
2frh√{1+(ln(D0/Dt)/π)2}
 Magnification factor
 R =ℇ /ℇ
m l 0

= {e(hl)sin(π-φ)}/sin(φ)
=e(hl)
From eqn ………… A= A0 e(-2hx)
for x=l
Al= A0 e(-2hl)

e(hl) =(A0/Al) (1/2)

Rm = e(hl) = (A0/Al) (1/2) =D0/Dl
 Rm= highest for stepped- hyperbolic
-exponential - conical

For exponential rectangular horn,

Of constant width W0 & thickness t(x) varying
according to exponential fn.
 A= A e(-2hx)
0
 W0t(x) = W0t0e(-2hx)
t(x) = t0e(-2hx)
THANK YOU