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This review paper reveals the literature on ultrasonic, chemical-assisted ultrasonic and rotary ultrasonic machining (USM) of glass material. The purpose of this review paper is to understand and describe the working principle, mechanism of material removal, experimental investigation, applications and influence of input parameters on machining characteristics. The literature reveals that the ultrasonic machines have been generally preferred for the glass and brittle work materials. Some other non-traditional machining processes may thermally damage the work surface. Through these USM, neither thermal effects nor residual stresses have been generated on the machined surface.

Various input parameters have the significant role in machine performance characteristics. For the optimization of output response, several input parameters have been critically investigated by the various researcher.

Some advance types of glasses such as polycarbonate bulletproof glass, acrylic heat-resistant glass and glass-clad polycarbonate bulletproof glass still need some further investigation because these materials have vast applications in automobile, aerospace and space industries.

Review paper will be beneficial for industrial application and the various young researcher. Paper reveals the detail literature review on traditional ultrasonic, chemical assisted ultrasonic and rotary USM of glass and glass composite materials.

The purpose of this paper is to investigate experimentally the effect of several input process factors, namely, feed rate, spindle speed, ultrasonic power and coolant pressure, on hole quality measures (penetration rate [PR] and chipping diameter [CD]) in rotary mode ultrasonic drilling of macor bioceramic material.

The main experiments were planned using the response surface methodology (RSM). Scanning electron microscopy was also used to examine and study the microstructure of machined samples. This study revealed the existence of dominant brittle fracture and little plastic flow that resulted in a material loss from the base work surface. Experiment findings have shown the dependability and adequacy of the proposed mathematical model.

The percentage of brittle mode deformation rises as the penetration depth of abrasives increases (at increasing levels of feed rate). This was due to the fact that at greater depths of indentation, material loss begins in the form of bigger chunks and develops inter-granular fractures. These stated causes have provided an additional advantage to increasing the CD over the machined rod of bioceramic. The desirability method was also used to optimize multi-response measured responses (PR and CD). The mathematical model created using the RSM method will be very useful in industrial revelation. Furthermore, the investigated answers’ particle swarm optimization (PSO) and teacher-learner-based optimization (TLBO) make the parametric analysis more relevant and productive for real-life industrial practices.

Macor bioceramic has been widely recognized as one of the most highly demanded innovative dental ceramics, receiving expanded industry approval because of its outstanding and superior characteristics. However, effective and efficient processing remains a problem. Among the available contemporary machining methods introduced for processing typical and advanced materials, rotary mode ultrasonic machining has been identified as one of the best suitable candidates for precise processing of macor bioceramics, as this process produces thermal damage-free profiles, as well as high accuracy and an increased material removal rate. The optimized combined setting obtained using PSO is feed rate = 0.16 mm/s, spindle speed = 4,500 rpm, ultrasonic power = 60% and coolant pressure = 280 kPa with the value of fitness function is 0.0508. The optimized combined setting obtained using TLBO is feed rate = 0.06 mm/s, spindle speed = 2,500 rpm, ultrasonic power = 60% and coolant pressure = 280 kPa with the value of fitness function is 0.1703.

Unconventional machining processes, particularly ultrasonic vibration cutting (UVC), can overcome such technical bottlenecks. However, the precise mechanism through which UVC affects the in-service functional performance of advanced aerospace materials remains obscure. This limits their industrial application and requires a deeper understanding.

The surface integrity and in-service functional performance of advanced aerospace materials are important guarantees for safety and stability in the aerospace industry. For advanced aerospace materials, which are difficult-to-machine, conventional machining processes cannot meet the requirements of high in-service functional performance owing to rapid tool wear, low processing efficiency and high cutting forces and temperatures in the cutting area during machining.

To address this literature gap, this study is focused on the quantitative evaluation of the in-service functional performance (fatigue performance, wear resistance and corrosion resistance) of advanced aerospace materials. First, the characteristics and usage background of advanced aerospace materials are elaborated in detail. Second, the improved effect of UVC on in-service functional performance is summarized. We have also explored the unique advantages of UVC during the processing of advanced aerospace materials. Finally, in response to some of the limitations of UVC, future development directions are proposed, including improvements in ultrasound systems, upgrades in ultrasound processing objects and theoretical breakthroughs in in-service functional performance.

This study provides insights into the optimization of machining processes to improve the in-service functional performance of advanced aviation materials, particularly the use of UVC and its unique process advantages.

The purpose of this paper, an original research paper, is to study the optimization of material removal rate (MRR) in ultrasonic machining of polycarbonate bulletproof glass and acrylic heat-resistant glass. The machining of these materials is a very tough job. There are so many constraints which need to be taken into account while machining, but without proper knowledge of material properties and machining parameters, machining is not possible. This paper gives basic knowledge about polycarbonate bulletproof and acrylic heat-resistant glass and provides ways as to how these types of materials are processed or machined.

The Taguchi method was utilized to optimize the ultrasonic machining parameters for drilling these advanced materials. The relationship between MRR and other controllable process parameters such as concentration of slurry, type of abrasive, abrasive grit size, power rating, concentration of HF acid and type of tool material has been analyzed by using the Taguchi approach.

Through the Taguchi analysis, it is concluded that types of abrasive and HF acid concentrations have a significant role to play in MRR for both materials; in which, type of abrasive have 72.91 and 72.96 percent contribution in MRR for polycarbonate bulletproof and acrylic heat-resistant glass, respectively. Similarly, HF acid concentration has 14.70 and 14.65 percent contribution in MRR for polycarbonate bulletproof and acrylic heat-resistant glass, respectively. The MRR was improved by 34.44 percent in polycarbonate bulletproof glass and 29.25 percent in acrylic heat-resistant glass.

After experimental investigation, the results of the Taguchi modal are validated.

Surgical gowns should be designed and produced using special techniques to provide barrier properties against potential risks during surgery and healthcare procedures. Ultrasonic welding is one of these methods used to produce surgical gowns with determined barrier properties. The purpose of this paper is to analyse bond strength and permeability properties of ultrasonically welded nonwoven fabrics and compare them with traditional sewing techniques.

In this study, ultrasonic welding of nonwovens was performed to demonstrate its use as an assembly method. Performance requirements in the design of surgical gowns were determined. Fabric strengths and bond strengths of ultrasonic-welded and traditionally sewn fabrics were analysed. The performance properties, i.e., bond strength, air and water resistance of the fabrics and the joints obtained by ultrasonic and classical sewing methods were studied.

As a result, it was found that ultrasonic welding technique is a suitable method for joining layers in surgical gown production bringing the advantages of high water resistance together with acceptable bond strength.

The current study focuses on the use of ultrasonic welding of nonwovens used for disposable protective surgical gowns. Ultrasound welding technique was presented as an alternative to classic assembly methods and ultrasonic welding technology was applied to different fabric combinations simulating different layers in different joining sections of a surgical gown.

The purpose of this paper is to study the effect of ultrasonic machining process parameters on surface quality while machining titanium alloy Ti-6Al-4V.

Effect of cryogenic treatment (CT) of tool and work material was also explored in the study. Taguchi’s L18 orthogonal array was chosen for design of experiments and average surface roughness was measured.

Different modes of fracture were detected at work surface corresponding to varied input process parameters. Slurry grit size, power rating and tool material along with CT of work material were found to be the significant parameters affecting surface quality.

The results obtained have been modelled using artificial neural network approach.

PRECISE shapes can be machined into ceramics, glass and other hard materials by Mafell equipment. The process employed is US‐erosion, otherwise known as ultrasonic machining. Mafell Ultrasonics GmbH, a West German company, has devoted much development work to making the process a practical method of manufacturing, with many potential applications in industry.

Over the past ten years about 200 computer‐controlled automatic sorting machines have been installed in Japan. The system described in this article, in use in a retail distribution centre, incorporates automatic ultrasonic volume measurement for calculation of freight charges, voice input, laser scanning and other sensing aids. Part of the system was described in this magazine in January 1981 — this article brings the story up to date.

Ultrasonic welding is an emerging apparel manufacturing technique. However, the applications are widely explored in the field of technical textiles, with less exploration in the apparel endues. The purpose of this study is to explore the application of ultrasonic welding in apparel by analyzing the impacts of different parameters.

This study analyzed the influence of ultrasonic welding parameters, including pressure, welding speed and ultrasonic power on the seam performances (seam strength, seam bursting strength, seam thickness and seam stiffness). The parameters are optimized using Box–Behnken experimental design to achieve better seam performances.

The properties of ultrasonic seams are influenced by welding and fabric properties. Ultrasonically welded seams showed better performances in the case of comfort properties of seams, whereas the functional properties are lesser compared to conventional seams.

The findings of the research clearly outline the level of influence of different parameters on the performance of the ultrasonically welded seams in knitted fabrics, which can greatly help in applying ultrasonic welding manufacturing methods in apparel manufacturing.