The kinematic approach to edge-chipping in rotary ultrasonic machining of Al2O3

Rotary ultrasonic machining (RUM) is useful in the machining of difficult-to-cut materials such as Al2O3. However, the edge-chipping occurs in the machined surface because of the brittleness of ceramics. The origin of edge-chipping is clear in general and several methods to its reduction have been published, briefly described in the article. The article brings new, kinematics based view on the edge-chipping origin and a method of its reduction. Theoretical equations were deduced based on the grit's trajectory characterized by machining variables of the processes. The equations have been employed in a full factorial experiment and experimental results fit the theoretical assumption satisfyingly. The edge-chipping was reduced by supposed method significantly.