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  • Ultrasonic Machining (USM) : Manufacturing Technology - II (ME - 312)

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    Sandeep Kang
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    Ultrasonic machining is a non-traditional machining process where abrasives in a slurry are driven at high velocity against a workpiece by a vibrating tool. The tool oscillates perpendicularly to the work surface at low amplitude and high frequency to enable material removal by the abrasives. The tool is slowly fed into the workpiece to shape it to the tool's form. Ultrasonic machining works well for hard and brittle materials with a hardness over 40 HRC and can achieve surface finishes between 0.25 to 0.75 μm. It is used to machine both electrically conductive and non-conductive materials for applications such as drilling multiple holes simultaneously in fragile materials like glass.

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    Ultrasonic machining is a non-traditional machining process where abrasives in a slurry are driven at high velocity against a workpiece by a vibrating tool. The tool oscillates perpendicularly to the work surface at low amplitude and high frequency to enable material removal by the abrasives. The tool is slowly fed into the workpiece to shape it to the tool's form. Ultrasonic machining works well for hard and brittle materials with a hardness over 40 HRC and can achieve surface finishes between 0.25 to 0.75 μm. It is used to machine both electrically conductive and non-conductive materials for applications such as drilling multiple holes simultaneously in fragile materials like glass.

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    11 views3 pages

    Ultrasonic Machining (USM) : Manufacturing Technology - II (ME - 312)

    Uploaded by

    Sandeep Kang
    Ultrasonic machining is a non-traditional machining process where abrasives in a slurry are driven at high velocity against a workpiece by a vibrating tool. The tool oscillates perpendicularly to the work surface at low amplitude and high frequency to enable material removal by the abrasives. The tool is slowly fed into the workpiece to shape it to the tool's form. Ultrasonic machining works well for hard and brittle materials with a hardness over 40 HRC and can achieve surface finishes between 0.25 to 0.75 μm. It is used to machine both electrically conductive and non-conductive materials for applications such as drilling multiple holes simultaneously in fragile materials like glass.

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    of 3

    Manufacturing Technology II (ME 312)

    Dr. M. Ravi Sankar


    MECHANICAL ENGINEERING DEPARTMENT
    I.I.T GUWAHATI- 208016
    e-mail : evmrs@iitg.ernet.in 1

    Ultrasonic Machining (USM)

    Abrasives in a slurry are driven at high velocity against


    work by a vibrating tool (low amplitude & high frequency)
    Tool oscillation is perpendicular to work surface
    Abrasives accomplish material removal
    Tool is fed slowly into work
    Shape of tool is formed into part
    FISHBONE DIAGRAM OF ULTRASONIC MACHINING

    SLURRY
    TOOL
    ABRASIVE TYPE DAMPING
    FEEDING
    VOLUME SINGLE OR MATERAIL PERFORMANCE
    MECHANISM MULTIPLE
    FRACTION CHARACTERS
    TOOLS
    DUCTILITY OF USM PROCESS
    GRIT SIZE
    TEMPERATURE
    VISCOSITY
    FINISH MRR
    LIQUID MEDIUM Tool wear rate
    CONCENTRATION GEOMETRY
    Cutting ratio
    AMPLITUDE MATERIAL
    TYPE OF OF VIBRATION
    surface
    f fi
    finish
    i h
    MATERIAL STATIC LOAD Form Geometric
    THICKNESS
    PIEZO TYPE OR
    HARDNESS FREQUENCY MAGNETOSTRICTIVE
    OF VIBRATION SHAPE
    STRENGTH

    POWER INPUT TOOL


    WORKPIECE HOLDER
    MACHINE 3

    PROCESS CAPABILITIES

    THE PROCESS WORKS BETTER FOR


    WORK MATERIAL HARD & BRITTLE MATERIAS
    HARDNESS HRC 40. CARBIDE,
    CERAMICS, W, GLASS, ETC.
    SURFACE FINISH 0.25 TO 0.75 m

    ACCURACY
    CONICITY IN THE DRILLING HOLE
    TO REDUCE CONICITY, NEGATIVE TAPER CAN BE PROVIDED
    OUT-OF-ROUNDNESS IN HOLES MAJOUR ISSUE
    TOLERANCE: 25 m
    UPPER LIMIT OF DEPTH OF DRILLED HOLD = 51 mm.
    ((EVEN UPTO 152 mm IN VERY SPECIAL CASES))
    ASPECT RATIO (DEPTH TO DIAMETER) = 40 : 1
    4
    PROCESS APPLICATIONS
    ELECTRICALLY NON-CONDUCTIVE & CONDUCTIVE BOTH
    MATERIALS CAN BE MACHINED.
    HARD & FRAGILE COMPONENTS.
    ALSO FOR MULTIPLE HOLES,
    IT CAN BE USED.

    USM tooll usedd to drill


    d ill multiple
    l i l holes
    h l simultaneously
    i l l into
    i fragile
    f il glass
    l disks
    di k
    PROCESSING OF SILICON NITRIDE TURBINE BLADES
    GLASS, CERAMICS, TITANIUM, TUNGSTEN, ETC.
    DRILLING, GRINDING, PROFILING.

    Dentist drilling holes in teeth


    USM IS ALSO USED IN CONJUNCTION WITH ECM, EDM,
    ECG, ETC
    5
    ALSO USED AS HYBRID PROCESSES: UECM, UEDM

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