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Ultrasonic Machining

Ultrasonic machining (USM) uses abrasive particles in a slurry that are driven by a vibrating tool against a workpiece to remove material. The tool vibrates at high frequency (15-30 kHz) and low amplitude (25-100 microns). As the tool vibrates, the abrasive particles indent both the tool and workpiece, removing material. Material is removed through crack initiation and brittle fracture. USM can machine hard, brittle materials and produces a burr-free finish. However, it has low material removal rates and high tool wear due to abrasive particles. USM is suitable for machining non-conductive materials that cannot be cut by other methods.

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171 views16 pages

Ultrasonic Machining

Ultrasonic machining (USM) uses abrasive particles in a slurry that are driven by a vibrating tool against a workpiece to remove material. The tool vibrates at high frequency (15-30 kHz) and low amplitude (25-100 microns). As the tool vibrates, the abrasive particles indent both the tool and workpiece, removing material. Material is removed through crack initiation and brittle fracture. USM can machine hard, brittle materials and produces a burr-free finish. However, it has low material removal rates and high tool wear due to abrasive particles. USM is suitable for machining non-conductive materials that cannot be cut by other methods.

Uploaded by

govind jodhani
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPTX, PDF, TXT or read online on Scribd
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ULTRASONIC MACHINING

• Introduction.
• Principle
• Equipment.
• Tool Materials and Tool Size and Abrasive Slurry.
• Cutting tool system design.
• Effect of parameter: Effect of amplitude and frequency and vibration.
• Effect of abrasive grain diameter.
• Effect of slurry, tool and work material.
• USM process characteristics: Material removal rate, tool wear, Accuracy, surface
finish, applications.
• Advantages & Disadvantages of USM.
INTRODUCTION

• What is the Difference between Frequency, Wavelength and Amplitude?

• Frequency tells us how many waves pass through a point at a second.

• Wavelength tells us the length of those waves.

• Amplitude tells us how big the wave is.

• In USM, 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).
PRINCIPLE

• The machining zone (between the tool and the work piece) 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.
EQUIPMENT
EQUIPMENT
Ultrasonic Machining consists of :

1. High Power sine wave generator.

2. Magnetostrictive Transducer.

3. Tool Holder.

4. Tool.
HIGH POWER SINE WAVE GENERATOR

• This unit converts low frequency (50 Hz) electrical power to high frequency (20kHz)
electrical power.

TRANSDUCER
• The high frequency electrical signal is transmitted to traducer which converts it into high
frequency low amplitude vibration.
• Essentially transducer converts electrical energy to mechanical vibration. There are two
types of transducer used
1. Piezo electric transducer
2. Magneto-stricitve transducer.
MAGNETOSTRICTIVE TRANSDUCER

• These transducer are made of nickel , nickel alloy sheets.


• Their conversion efficiency is about 20-30%.
• Such transducers are available up to 2000 Watts.
• The maximum change in length can be achieved is about 25 microns.

TOOL HOLDER OR HORN


• The tool holder holds and connects the tool to the transducer. It virtually transmits the
energy and in some cases, amplifies the amplitude of vibration.
• Commonly used tool holders are Monel, titanium, stainless steel.
• Tool holders are more expensive, demand higher operating cost.
TOOL

• Tools are made of relatively ductile materials like Brass, Stainless steel or Mild steel so
that Tool wear rate (TWR) can be minimized.
• The value of ratio of TWR and MRR depends on kind of abrasive, work material and tool
materials.
MECHANISM OF MATERIAL REMOVAL
Material Removal Models in USM

The following are the Material Removal Models used in USM

1. Throwing of abrasive grains.

2. Hammering of abrasive grains.

3. Cavitations in the fluid medium arising out of ultrasonic vibration of tool.

4. Chemical erosion due to micro –agitations.


APPLICATIONS
• Machining of cavities in electrically non-conductive ceramics
• Used to machine fragile components in which otherwise the scrap rate is high
• Used for multistep processing for fabricating silicon nitride (Si3N4) turbine blades
• Large number of holes of small diameter could be machined. 930 holes with 0.32mm has
been reported ( Benedict, 1973) using hypodermic needles
• Used for machining hard, brittle metallic alloys, semiconductors, glass, ceramics, carbides
etc.
• Used for machining round, square, irregular shaped holes and surface impressions.
• Used in machining of dies for wire drawing, punching and blanking operations
• USM can perform machining operations like drilling, grinding and milling
operations on all materials which can be treated suitably with abrasives.
ADVANTAGES

• It can be used machine hard, brittle, fragile and non conductive material
• No heat is generated in work, therefore no significant changes in physical structure of
work material
• Non-metal (because of the poor electrical conductivity) that cannot be machined by EDM
and ECM can very well be machined by USM.
• It is burr less and distortion less processes.
• It can be adopted in conjunction with other new technologies like EDM,ECG,ECM.
DISADVANTAGES

• Low Metal removal rate.


• It is difficult to drill deep holes, as slurry movement is restricted.
• 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.
• USM can be used only when the hardness of work is more than 45 HRC.
SAMPLES
ULTRASONIC MACHINE

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