Ultrasonic Machining 7 Parts, Working, Pros, Cons, AppLications [PDF]

In this article, we shall cover the definition, parts, working principle, advantages, disadvantages, and application of Ultrasonic Machining (USM). We have provided a PDF for the same. Ultrasonic Machining is a non-traditional machininging process in which the Harder material is machined. These machines have great properties like

  • A high degree of accuracy and Surface texture.
  • The high rate of metal removal and so on.
Ultrasonic Machining
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Definition of Ultra Sonic Machining

Ultrasonic machining is a Mechanical machining method. The other mechanical machining method is Abrasive jet Machining. Waves are generated using magnetostrictive effects which are further converted into mechanical vibration.

Ultrasonic Machining
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Magnetostriction means the change in dimensions occurring in ferromagnetic due to an alternating magnetic field. No heat is generated in this process and the tool vibrates longitudinally at 20 to 30 kHz with an amplitude between 0.01 to 0.06 mm. The tool has the same shape as the cavity to be machined.

Parts of Ultrasonic Machining

The Parts of Ultrasonic Machine are as follows

  • Power Supply
  • Electro-mechanical transducer
  • Velocity Transformer
  • Tool
  • Abrasive Slurry
  • Abrasive gun
  • Workpiece
Ultrasonic Machining Parts
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Power Supply

To start, the machining process power is required. This is an essential component. As the diagram shows the first is connected to the power supply.

Electro-mechanical Transducer

An electromechanical transducer is connected to the AC supply. The transducer converts an electrical signal to a mechanical signal whereas the electromechanical transducer is used to generate mechanical vibration.

Velocity Transformer

It holds the tool firmly.

Tool

The tool should be designed when the operation is performed does not to lead to brittle fracture of it. Therefore the tool is made of tough, strong, and ductile materials like steel, stainless steel or HSS (High stainless steel), Mild Steel, etc.

Abrasive slurry

A water-based slurry of abrasive particles is used as an abrasive slurry in this machining. Aluminum oxide, Silicon carbide, and Boron carbide are used as abrasive particles in this slurry. 

Abrasive Gun

An abrasive gun is used to supply an abrasive slurry, which is a mixture of abrasive grain and the water in between the tool-workpiece interface under a definite pressure.

Workpiece

The machines perform several techniques on the workpiece which are as follows

  • Machining very precise and intricate shaped articles.
  • Drilling the round holes of any shape.
  • Grinding the brittle materials.
  • Profiling the holes.
  • Engraving
  • Trepanning and coining
  • Threading

Working Principle of ultrasonic Machining

It consists of an electromechanical transducer connected to the AC supply. Velocity transformer which holds the tool firmly. An abrasive gun is used to supply an abrasive slurry, which is a mixture of abrasive grain and the water in between the tool-workpiece interface under a definite pressure.

Video By AniMech

When the AC power is supplied with high frequency, the transducer starts vibrating longitudinally by magnetostriction, which is transmitted to the penetrating tool through a mechanical focusing device called a Velocity transformer. As the tool vibrates it is pressed on the work surface with light force and allowing the abrasive slurry to flow through between the tool-workpiece interface.

The Impact force arising out of the vibration of the tool end and the flow of abrasive slurry causes thousand of microscopic grains to remove from work material by abrasion. Abrasive like Aluminum Oxide, Silicon Carbide can be used. The tool is made of soft ductile material like copper or brass, soft steel or stainless steel.

schematic diagram of ultrasonic machining
Photo By Four30

Applications of ultrasonic Machining

  • Machining very precise and intricately shaped articles.
  • Drilling the round holes of any shape.
  • Grinding the brittle materials.
  • Profiling the holes.
  • Engraving
  • Trepanning and coining
  • Threading
  • Slicing and broaching hard materials.
  • Machining the glasses, and ceramics.
  • Machining the precise mineral stones, tungsten.
  • Piercing of dies and for parting off operation.
  • This is precise enough to be used in the creation of micro-electro-mechanical system components such as micro-structured glass wafers
  • Diamond is cut for the desired shapes.
Ultrasonic Machining Applications
Photo by Boyfre

Advantages of ultrasonic Machining

  • This process is used for drilling both circular and non-circular holes in very hard materials like carbide, ceramics, etc.
  • This process is best suited for brittle materials.
  • The machining operation is simple and requires less time.
  • This process is economical.
  • Glass, Ceramic, and tungsten can be machined.
  • A semi-skilled operator can operate the machine.
  • Better efficiency can be achieved.
  • Good surface finish.
  • It is suitable for both conducting and non-conducting materials.
  • High accuracy can be achieved.

Disadvantages of Ultrasonic Machining

  • Low material cutting rate.
  • High power consumption.
  • Low penetration rate.
  • The process is limited to the machined surface of a small size.
  • Shorter tool life.
  • Ultrasonic vibration machining can only be used on materials with a hardness value of at least 45 HRC (Rockwell Hardness).

FAQ

What Part Of The Ultrasonic Machine Generates High-Frequency Ultrasonic Energy?

When the AC power is supplied with high frequency, the transducer starts vibrating longitudinally by magnetostriction

What Are The Advantages Of Ultrasonic Machining?

  • This process is used for drilling both circular and non-circular holes in the workpiece
  • Very hard materials like carbide, ceramics, etc. are machined easily
  • This process is best suited for brittle materials.
  • The machining operation is simple and requires less time.

What Are Some Applications Of Ultrasonic Machining?

It is used for the following

  • Machining very precise and intricate-shaped articles.
  • Drilling the round holes of any shape.
  • Grinding the brittle materials.
  • Profiling the holes.

What is Ultrasonic Vibration Assisted Machining

Ultrasonic Vibration Assisted Machining (UVAM) is a cutting-edge technique that combines traditional machining with high-frequency vibrations. It involves the application of ultrasonic vibrations to the cutting tool, resulting in enhanced material removal rates, reduced cutting forces, improved surface quality, and extended tool life. UVAM improves machining efficiency and precision by leveraging the energy of ultrasonic waves during the cutting process.

What is Ultrasonic Abrasive Machining

Ultrasonic Abrasive Machining (UAM) is an innovative method that employs ultrasonic vibrations in conjunction with abrasive particles for precision material removal. It involves the use of a slurry containing abrasive particles that are propelled onto the workpiece under the influence of high-frequency vibrations. This process facilitates efficient material removal, improved surface finish, and the ability to work on intricate shapes or hard-to-reach areas. UAM offers enhanced control and precision in abrasive machining operations.

What is the Ultrasonic machining material removal cost

The cost of material removal in Ultrasonic Machining (USM) depends on various factors such as the type of material, workpiece geometry, and machining parameters. Generally, USM is considered a cost-effective process due to its ability to work on hard and brittle materials without causing thermal damage. However, specific cost estimates can vary based on individual project requirements, tooling costs, and other related factors. It is advisable to consult with experts or conduct a feasibility study to determine the precise cost implications for a particular application.

Conclusion

To conclude, Ultrasonic Machining (USM) is an advanced manufacturing process that uses high-frequency mechanical vibrations to remove material from hard and brittle workpieces. The article has covered the definition, parts, working principle, advantages, disadvantages, and applications of this process. USM is highly precise and can achieve complex shapes with a high surface finish. It also offers advantages such as low thermal impact, no tool wear, and no residual stress.

However, it has some limitations such as low material removal rate, high equipment cost, and limited application on certain materials. USM finds its applications in various industries such as aerospace, medical, and electronics. In conclusion, understanding the working and limitations of USM is essential to select the appropriate machining process for a given application.

References

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