Ultrasonic machining effects on the surface finish and strength of silicon carbide ceramics

Ultrasonic machining experimental investigation was conducted on Silicon Carbide (SiC) and 20% volume titanium diboride-silicon carbide (TiB2/SiC) composite. Rectangular 304 stainless steel tools were used with three different abrasive grit sizes of silicon carbide (SIC) and boron carbide (B4C) abrasives were used while all other machining parameters were kept constant. The effects of the different abrasive sizes and types on the workpiece materials in terms of material removal rate, surface integrity, and flexural strength are presented. The #220 grit size for both abrasive types yielded the best overall results. Although both materials responded well to the ultrasonic machining process, the TiB2/SiC composite exhibited the better surface roughness and characteristic bending strength.