Abstract
This paper describes the optimization of glass holes made by rotary ultrasonic machining, using a statistical model and mathematical programming. The characteristic being optimized was the glass hole diameter, with three machine factors as control factors and one operational mode. The control factors were ultrasonic vibration power, feed speed and rotation speed of the tool. The operational mode was tool feed mode. In particular, we identified this operational mode as a key factor in achieving high quality, high productivity and low cost. In order to develop a statistical model, we first designed and executed an experiment to collect hole diameter data. Next, we built a statistical model of the hole diameter using the aforementioned factors and a mode. Then we optimized the model using mathematical programing in three different scenarios. Scenario 1 was optimization for high quality at feed mode level 1. Scenario 2 was optimization for high productivity at feed mode level 2. Scenario 3 was total optimization profitable for both feed mode level 1 and level 2. Finally, we discussed the three sets of results of this optimization, while considering the specifications of the hole diameter. In conclusion, machining optimization based on a statistical model is effective.
