An Experimental Investigation of Rotary Ultrasonic Machining and Mechanical Property Evaluation on Hand Layup Fabricated Hybrid Composite

Rotary ultrasonic machining (RUM) is a feasible solution for the cost-effective machining of brittle and hard materials. This study aims to provide new information based on the drilling of hybrid composites of natural fibre and glass fibre using RUM (rotary ultrasonic machining) to improve the quality of machined holes while reducing machining costs, as well as to investigate the effects of machining and tool factors on output variables. To explore the properties of small-diameter drilling for hybrid composite, the surface roughness along the feed direction of the drilled hole is measured. During RUM drilling, the influence of the process parameters (feed rate, depth of cut, tool rotation speed, and ultrasonic power) and output variables (MRR and SR) on the manufactured composites were analysed. In addition, the composite has undergone mechanical testing to analyse and compare its mechanical properties. The results indicate that MRR grows as a function of all process factors, with material combination and feed rate being the most effective and important. SR rises with feed rate, whereas frequency has the opposite effect. All process factors except ultrasonic power have a considerable influence on SR variation. Comparing the mechanical properties of composite materials, it was discovered that the combination material C2 had more hardness and flexural strength than all other composite combinations. But in terms of tensile strength, C3 material is superior to other composite materials.