Scribd
Upload
47 views3 pages

KME - 403 - 20200325 Unit 05 Unconventional Machining Processes

Ultrasonic machining is a non-traditional machining process where a tool oscillates at high frequency against a workpiece flooded with an abrasive slurry. The abrasive particles act as indenters, removing material from both the tool and workpiece through crack initiation and brittle fracture. USM can machine hard, brittle, electrically non-conductive materials like ceramics and is used to drill small holes and complex shapes that would be difficult or damage workpieces through other processes. However, USM has low material removal rates and tool wear can be high.

Uploaded by

Ayush Trivedi
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
47 views3 pages

KME - 403 - 20200325 Unit 05 Unconventional Machining Processes

Ultrasonic machining is a non-traditional machining process where a tool oscillates at high frequency against a workpiece flooded with an abrasive slurry. The abrasive particles act as indenters, removing material from both the tool and workpiece through crack initiation and brittle fracture. USM can machine hard, brittle, electrically non-conductive materials like ceramics and is used to drill small holes and complex shapes that would be difficult or damage workpieces through other processes. However, USM has low material removal rates and tool wear can be high.

Uploaded by

Ayush Trivedi
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 3

KME_403_20200325

Unit 05
Unconventional Machining Processes
(LECTURE 03)

Ultrasonic Machining:

Definition: Ultrasonic Machining is a non-traditional process, in which abrasives contained in a


slurry are driven against the work by a tool oscillating at low amplitude (25-100 microns) and
high frequency (15-30 kHz).

Process: Ultrasonic machining is a mechanical type non-traditional machining process. It is


employed to machine hard and brittle materials (both electrically conductive and non conductive
material) having hardness usually greater than 40 HRC. The process was first developed in
1950s and was originally used for finishing EDM surfaces.

In ultrasonic machining, tool of desired shape vibrates at ultrasonic frequency ( 19 to 25 kHz. )


with an amplitude of 15-50 Microns over work piece. Generally tool is pressed down with a feed
force F. Between the tool and work, machining zone is flooded with hard abrasive particles
generally in the form of water based slurry. As the tool vibrates over the work piece, abrasive
particles acts as indenter and indent both work and tool material . Abrasive particles , as they
indent , the work material would remove the material from both tool and work piece. In
Ultrasonic machining material removal is due to crack initiation, propagation and brittle fracture
of material. USM is used for machining hard and brittle materials, which are poor conductors of
electricity and thus cannot be processed by Electrochemical machining ( ECM) or Electro
discharge machining (EDM). The tool in USM is made to vibrate with high frequency on to the
work surface in the midst of the flowing slurry. The main reason for using ultrasonic frequency
is to provide better performance. Audible frequencies of required intensities would be heard as
extremely loud sound and would cause fatigue and even permanent damage to the auditory
apparatus

Applications

1.Machining of cavities in electrically non-conductive ceramics

2.Used to machine fragile components in which otherwise the scrap rate is high

3.Used for multistep processing for fabricating silicon nitride (Si3N4) turbine blades 4.Large
number of holes of small diameter. 930 holes with 0.32mm has been reported ( Benedict, 1973)
using hypodermic needles

5.Used for machining hard, brittle metallic alloys, semiconductors, glass, ceramics, carbides etc.

6.Used for machining round, square, irregular shaped holes and surface impressions. 7.Used in
machining of dies for wire drawing, punching and blanking operations

8.USM can perform machining operations like drilling, grinding and milling operations on all
materials which can be treated suitably with abrasives.

9.USM has been used for piercing of dies and for parting off and blanking operations. 10.USM
enables a dentist to drill a hole of any shape on teeth without any pain 11.Ferrites and steel parts ,
precision mineral stones can be machined using USM 12.USM can be used to cut industrial
diamonds

13.USM is used for grinding Quartz, Glass, ceramics

14.Cutting holes with curved or spiral centre lines and cutting threads in glass and mineral or
metallo-ceramics

Advantages

1. It can be used machine hard, brittle, fragile and non conductive material

2. No heat is generated in work, therefore no significant changes in physical structure of work


material 3. Non-metal (because of the poor electrical conductivity) that cannot be machined by
EDM and ECM can very well be machined by USM.

4. It is burr less and distortion less processes.

5. It can be adopted in conjunction with other new technologies like EDM,ECG,ECM.


Disadvantages

1. Low Metal removal rate

2. It is difficult to drill deep holes, as slurry movement is restricted.

3. Tool wear rate is high due to abrasive particles. Tools made from brass, tungsten carbide, MS
or tool steel will wear from the action of abrasive grit with a ratio that ranges from 1:1 to 200:1

4. USM can be used only when the hardness of work is more than 45 HRC.

You might also like