Ultrasonic vibration assisted machining (UVAM)

1. Literature Review
What is Ultrasonic?
 Ultrasonic refers to any application of sound waves that have a higher frequency
than the human audible range. The field of ultrasonic thus involves the use of
sound waves outside the audible range for humans.
 Ultrasonic consist of frequencies greater than 20kHz and excess of 25 MHz.
 For examples, ultrasonic waves mostly uses or found in many application such as
plastic welding, medicine, jewelry cleaning and nondestructive test.
 Within nondestructive test, ultrasonic waves give us the ability to “see through”
solid material and can detect surface without affecting the material.

Figure 1 : Examples of the ultrasonic application.

Applications of ultrasonic in science and engineering.

 To detect flaws or cracked in metals.

 Used to detect ships and submarine or iceberg in the ocean.
 Its use to weld some metals that cant be welded by electric or gas welding.
One of the process using Ultrasonic.

 Ultrasonic Vibration Assisted Machining (UVAM).

Ultrasonic Vibration Assisted Machining.

 Ultrasonic Vibration Assisted Machining is a process which makes use of a micro

scale with high frequency vibrationapplied to a cutting tools to improve the
effectiveness of material removal part or workpiece.
 The principle of this ultrasonic vibration is to make the workpiece’s tool
interaction a microscopically non monotonic process to facilate chip separation
and to reduce machining forces.
 It can also reduce deformation zone in a workpiece under machining.

Several types of UVAM processes.

 Differentiated by the directions of the vibrations introduced relativce to the

cutting direction.
 The application of UVAM to a wide range of workpiece materials have shown
that the process can improve machining performance.

This is the some comprehensive discussion and some review about the UVAM such as
cutting kinematics and dynamics, effect of workpiece material and wear of cutting tools,
involving a wide range of workpiece material including metal alloys, ceramic and
composite materials.

High Power Ultrasound

 HPU is the application of intense acoustic energy to create change in a material or

process.
 Transducer is heart of system
 Converts electrical energy to mechanical energy.
 Establishes resonance.
A note on Vibrations

 Longitudinal mode is single most important mode of vibration.

Graph 1 : An examples of graph that occur a vibration.

Uses vibration in cutting.

 A means of working metal by cutting in which the tools is vibrated relative to the
workpiece, in adition to its basic movement.
 Vibration is used to break up shavings in working difficult materials (stainless and
heat resistance steels).
 Low frequency vibrators with mechanical, pneumatic or hydraulic drive (the
frequency of the induced vibration does not excess 50 Hertz are used for crushing
shavings.
 For vibration cutting of hard to work materials, magnetostrictive,
magnetomechanical, piezoelectric, electrodynamic and hydraulic vibrators in
which frequency of the induced vibrations is greater than 100 Hz are used.
 In vibration cutting with crushing of shavings, the vibrations are applied axially
(in the direction of the feed) efficient and reliable operation is obtained in
processing a surface to the fifth or sixth grades of finishwith the given accuracy
and tool hardness.
 Vibrations for the purpose of machin ability may be applied tangentially in
accordance with the circumferential speed with a variable effect on the layer
being cut at virtually constant sections of cutting, feed and cutting depth.
 Does not use gearing systems providing radial vibrations since they lead to a
sharp deterioration in the grade of surface finish.
2. Concept of UVAM, frequency, amplitude, resonance.

Vibration cutting ratio

 The frequency and amplitude are the most dominant factors for this ratio.
However, the federate and spindle speed can make small changes which can
provide the optimum chip removal efficiency. Focused on the convential cutting
with the ratio of contact cycle in one. That means that for 100% of cutting time
the rake face is in contact with the work piece, which is hugely different from 2D
VAM. Contact and non contact tool ratios can be obtained by using this eqution,

𝑇𝑖𝑚𝑒𝑛𝑜𝑛𝑐𝑜𝑛𝑡𝑎𝑐𝑡
𝐶𝑢𝑡𝑡𝑖𝑛𝑔 𝑅𝑎𝑡𝑖𝑜 = × 100%
𝑇𝑖𝑚𝑒𝑡𝑜𝑡𝑎𝑙 𝑡𝑖𝑚𝑒

 Time noncontact the sum of time that the rake faces or tool tip is not in contact
with the workpiece. Time totaltime I ssum of total time the tool is in cutting area.
The higher Cutting ratio, the more benefit for chip removal efficiency, cutting
force reduction, cutting temperature, extend tool life.

]
𝐴 max 𝑐ℎ𝑖𝑝
𝐴𝑚𝑝𝑙𝑖𝑡𝑢𝑑𝑒 𝐹𝑒𝑒𝑑 = 𝑓𝑡𝑜𝑜𝑡ℎ

 Where the A max chip is the maximum amplitude of chip thickness and F tooth is
feed per tooth. The trajectory of the tool paint will reveal the regularity which is
affecting the workpiece thus taken into account from the area of cutting.

What is Ultrasonic Machining?

 Ultrasonic Vibration + Conventional Machining (Drilling, Reaming, Turning,
Milling,..)
 This results changing the cutting process.
 Reducing dynamic friction.
 Reduces cutting forces.
 Reduces heat generated in cut.
Figure 2 : Sinking a hole in a workpiece with an ultrasonically vibrating tool driving an
abrasive slurry.

Fundemental Ultrasonic System

 Ultrasonic Module
 20 kHz nominal resonant frequency.
 5-25𝜇m tool tip displacement.
 ER-32 spindle coolant.
 Figure 3 : Ultrasonic Assisted Machining Module.

Acoustech Power Supply

 Operating bandwidth of 19,000 – 21,000Hz

 Controls operating frequency.
 Maintains desired tool tip displacement.
 2.5kW maximum output power.

System Characterization.

 Amplitude
 Critical process variable.
 Measured as tool tip displacement in peak to peak micrometer values.

 Frequency
 Not a variable, determined by natural resonance of drill.
 Changes with tool length and geometry.
 Must be considered for every tooling application.
  Matching process
 Critical velocity.

Graph 2 : Shows the Ultrasonic Vibration and the Penetraion of Granular Material.

A note on bandwidth

 Some shifting of resonant frequency can be accommodated.

 Presence of other modes.
 Amplitude is most critical parameter.
 Loading effects.
 Higher power required to maintain resonance.
Graph 4 : Amplitude Profile During Drilling of Off tuned System.

Figure 4 : Examples of bandwidth

3. Equipment needed including the electrical setup and its machining processes.

Figure 5 : Equipment that needed in the process.

Illustration of experimental setup and spatio temporal model fit for UV-A pelleting.
Process

 An ultrasonically vibrating consist of two major components, an electro acoustic

transducer and a sonotrode, attached to an electronic control unit with a cable. An
electronic oscillator in the control unit produces an alternating current oscillating at a
high frequency that is usually between 18 and 40kHz in the ultrasonic range. The
transducer converts the oscillating current to a mechanical vibration.
 A constant stream of abrasive slurry flows between the sonotrode and work piece.
The sonotrode remove material from the work piece by abrasion where it contacts’s
profile into the work piece.
 Ultrasonic vibration machining allows extremely complex and non uniform shapes to
be cut into the work piece with a very high precision.
4. Application and implementation producing product.

 Machining of cavities in electrically non conductive ceramics.

 Used to machine fragile components in which otherwise the scap rate is high.
 Used for multistep processing for fabricating silicon nitride (Si3N4) turbine blades.
 Used for machining hard, brittle metallic alloys, semiconductors, glass, ceramics, and
carbides.
 Used for maching round, square, irregular shaped holes and surface impressions.
 Also used in machining of dies for wire drawing, punching and blanking operations.
 USM has been used for percing of dies and for parting off and blanking operations.
 USM enables a dentist to drill a hole of any shape on teeth without any pain.
 Ferrites and steel parts, precision mineral stones can be machined using USM.
 Can be used to cut industrical diamonds.
 USM is used for grinding Quartz, glass and ceramics.
 Cutting holes with curved or spiral centre lines andcutting threads in glass and
mineral or metallo-ceramics.
 USM also can perform maching operations like drilling, grinding and milling
operations on all materials which can be treated suitably with abrasives.
 Large number of holes of small diameter. 930 holes with 0.32mm has beed reported
(Benedict. 1973) using hypodermic needles.
5. Advantages and disadvantages compared to conventional machining.

There are many advantages of UVAM that is :-

 For machining of hard and brittle materials.

 Produces less heat.
 Various hole cut shapes due to the vibratory motion of the tool.
 Threading of hard materials.
 For drilling of non-ciccular holes in materials like grass.
 Produces fine finished and structured results.

The disadvantages of UVAM is :-

 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
 Skilled labor is operated on the machine.
 Unnecessary large grain size cause defect.
 Repair should be necessary.
 It is difficult to machine deep holes, as the slurry movement is restricted.
 Low machining to the conventional machining process.
 USM can be used only when the hardness of work is more than 45 HRC.

Conventional Ultrasonic Vibration Comments

 Machining Assisted Machining
Chip thickness Chip always thicker -Chip thickness Conv. machining
and depending on thinner and strongly cut a workpiece in
feedrate and spindle depending on the each single rotation
speed only. amplitude, spindle in one cycle, but
speed, smaller 2D VAM cut the
amplitude, and workpiece much
thinner chip smaller cause the
produced. frequency and
- The consecutive amplitude effect.
overlapping toolpaths
results in chips that
are thinner than the
depth of cut.

Chip formation Chip always - Conv. machining

continuous and Discontinuous/shorter cut a workpiece in
depending on chip strongly each single rotation
feedrate and spindle depending on the in one cycle, but
speed only. frequency, amplitude 2D VAM cut the
and spindle speed. workpiece much
Higher frequency, smaller cause the
smaller chip frequency and
produced. amplitude effect.
- Instantaneous uncut
chip thickness at each
point in the tool path
is less than the depth

Table 1 : Comparison investigation between Conventional Machining and UVAM

6. The estimation costing and economics of using the UVAM.

 The process is non thermal, non chemical and non electrical, leaving the chemcical
and physical properties of the workpiece unchanged. This low stress process
translates into high reliability for your critical applications.
 Multiple featured can be machined at the wafer or substrate level simultaneously and
the process is scalable. This process often the highest quality and lowest cost.
Conclusion

 As non tradional high efficiency method, UVA cutting has been widely
investigated. Its high maching capabilities, including low cutting forces, long tool
life, high surface integrity and excellent cutting accuracy are effective on the
machining of many types of materials from macro, micro to nano scales and have
shown potential in industrial applications. However, there are many issues to be
clarified before a UVAM process can be optimized. The following are some of
the authors’ personal perspectives for further reaserach.
 High vibration frequency and the amplitude would improve the cutting
performance of a UVAM system. However, due to the limitation of the hardware
structures of materials, developing UVAM systems of high vibration frequency
and amplitude is one the challenge.
 Compared to convential machining process, UVA cutting can often have a more
greater critical depth of cut according to experimental observations.