Machining and Surface Characterization of Si3N4-Based Ceramic During Recently Developed USMM Using SiC Abrasives: An Experimental Investigation and Simulation Approach

In sophisticated engineering machining, ceramic materials are in great demand in today’s precision industries because they have a wide range of potential applications, including automobiles, aircraft, and biomedical engineering. Silicon nitride ceramics (Si₃N₄) are difficult to manufacture using conventional machining processes. Modern technology allows Ultrasonic Micro-machining (USMM) to create almost any kind of material. Abrasive particles made of silicon carbide are used in this research work to look into the Si₃N₄ USMM process parameters. The physical structure and chemical composition have been examined in a scanning electron microscope with an integrated energy-dispersive X-ray analyzer. Particle swam optimization and Response Surface Methodology (RSM) desirability were the two types of optimizations used to find the best USMM process parameters. It has been shown that both techniques can be used together to get the best Material Removal Rate (MRR). The best settings were Slurry Concentration: 50 (g/l), Power Rating: 329 (W), and Tool Feed Rate: 1.06 (mm/min). Similarly, to minimize Overcut (OC) and Taper Angle (TA), the ideal method is to use a slurry concentration of 50 (g/l), a power rating of 400 (W), and a tool feed rate of 1.2 (mm/min). Finally, using the RSM, the USMM process was optimized in a way that maximized the MRR while minimizing OC and TA. It was found that the slurry concentration of 42.7 g/l, the power rating of 357.6 W, and the tool feed rate of 1.2 mm/min were the ideal settings for the USMM process.