Ultrasonic machining (Usm)

R.K. RANA [LECTURER

M.Tech (P), B.Tech, LMIEI

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Ultrasonic Machining Process (USM)

� Ultrasonic machining (USM) is a mechanical material removal process.

� It is used to erode material in the form of fine holes and cavities in hard or

workpiece through the use of formed tools, vibrations of high frequency along

with the use of a suitable abrasive slurry

� The Ultrasonic Machining (USM) process is suitable for machining brittle

materials such as glass, ceramics and semiconduct

operations to provide intricate shapes and workpiece profiles.

� The USM is a non-thermal and non

the chemical, physical or metallurgical properties of

� It is therefore being widely used in the manufacturing of hard and brittle

materials which are normally unfeasible to machine by the traditional methods.

� The cutting is actually performed by the abrasive particles which are suspended

in the slurry1 (fluid).

� Ultrasonic machining accomplishes the material removal through the

action of the grit3-loaded slurry which circulates between the tool and the

workpiece.

� Small amplitudes and high frequency of vibrations are given to the tool, typically

in the range of 10–20

are accelerated towards the workpiece surface by the oscillating action of the

tool - through repeated abrasions, the tool further machines a cavity of cross

section identical to its own. The mater

grains by shear deformation.

� Different mechanisms could be attributed to this material process such as brittle

fracturing of the work material, impact action of abrasives, cavitation and

chemical reaction due to

accuracy is directly dependent on the geometry of the tool. The schematic of

ultrasonic material removal process is shown in

schematic of ultrasonic machine in figure

1 Slurry: A suspension of insoluble particles

2 Abrading: Rub hard or scrub

3 Grit: A hard coarse-grained siliceous sandstone

LECTURER] YouTube.com/RamakantRana

ULTRASONIC MACHINING

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Ultrasonic Machining Process (USM)

Ultrasonic machining (USM) is a mechanical material removal process.

It is used to erode material in the form of fine holes and cavities in hard or


with the use of a suitable abrasive slurry-mix.

The Ultrasonic Machining (USM) process is suitable for machining brittle

materials such as glass, ceramics and semiconductors for increasingly complex

operations to provide intricate shapes and workpiece profiles.

thermal and non-chemical process which creates no change in

the chemical, physical or metallurgical properties of the workpiece.

eing widely used in the manufacturing of hard and brittle


The cutting is actually performed by the abrasive particles which are suspended

hining accomplishes the material removal through the

loaded slurry which circulates between the tool and the

Small amplitudes and high frequency of vibrations are given to the tool, typically

20 μm at 20–40 kHz. The hard abrasive particles in the slurry


through repeated abrasions, the tool further machines a cavity of cross

section identical to its own. The material removal takes place is the form of fine

grains by shear deformation.

Different mechanisms could be attributed to this material process such as brittle


chemical reaction due to the slurry. The workpiece shape and dimensional


ultrasonic material removal process is shown in following figure and the

ltrasonic machine in figure.

Slurry: A suspension of insoluble particles

grained siliceous sandstone

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www.RamakantRana.blogspot.com

Ultrasonic machining (USM) is a mechanical material removal process.

It is used to erode material in the form of fine holes and cavities in hard or brittle


The Ultrasonic Machining (USM) process is suitable for machining brittle

ors for increasingly complex

chemical process which creates no change in

eing widely used in the manufacturing of hard and brittle


The cutting is actually performed by the abrasive particles which are suspended

hining accomplishes the material removal through the abrading2

loaded slurry which circulates between the tool and the

Small amplitudes and high frequency of vibrations are given to the tool, typically

40 kHz. The hard abrasive particles in the slurry


through repeated abrasions, the tool further machines a cavity of cross

ial removal takes place is the form of fine

Different mechanisms could be attributed to this material process such as brittle


the slurry. The workpiece shape and dimensional


figure and the

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Figure: Schematic of Ultrasonic Material Removal Process

Figure

Historical Development of US

� The historical development of Ultrasonic Machining (USM) started through the

research works in 1927.

� During investigating the

that the surface of a container which was holding the suspended abrasives

disintegrated as soon as the tip of an ultrasonically vibrating tra

placed close to it.

� Interestingly, the shape of t

tip of the transducer.

� In the early 1950’s industries started realizing its benefits and the production of

ultrasonic machines began thereafter. A wide range of brittle materials, including

glass, ceramics and diamond can be effectively machined through this process.




ematic of Ultrasonic Material Removal Process

Figure: Schematic of Ultrasonic Machine

Historical Development of USM:

The historical development of Ultrasonic Machining (USM) started through the

research works in 1927.

During investigating the ultrasonic grinding of abrasive powders, it was found


disintegrated as soon as the tip of an ultrasonically vibrating transducer was

Interestingly, the shape of the cavity, thus produced accurately reprod

In the early 1950’s industries started realizing its benefits and the production of


and diamond can be effectively machined through this process.

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The historical development of Ultrasonic Machining (USM) started through the

ultrasonic grinding of abrasive powders, it was found


nsducer was

he cavity, thus produced accurately reproduced the

In the early 1950’s industries started realizing its benefits and the production of


and diamond can be effectively machined through this process.

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Machine

The basic mechanical structure of an USM is very similar to a drill press.

However, it has additional features to carry ou

The workpiece is mounted on a

the tool using a 2 axis table.

The table can further be lowered or raised to accommodate work of different thickness.

The typical elements of an USM are (Following Figure

• Slurry delivery and return

• Feed mechanism to provide a downward feed for

machining

• The transducer, which generates the ultrasonic vibration

• The horn or concentrator, which mechanically amplifies the vibration to the

required amplitude of 15

Figure: Schematic view of an Ultrasonic Machine

The ultrasonic vibrations are produced by the transducer.

The transducer is driven by suitable signal generator followed by power amplifier.

The transducer for USM work




The basic mechanical structure of an USM is very similar to a drill press.

However, it has additional features to carry out USM of brittle work material.

The workpiece is mounted on a vice, which can be located at the desired position under


ements of an USM are (Following Figure)

urry delivery and return system

Feed mechanism to provide a downward feed force on the tool during

The transducer, which generates the ultrasonic vibration

The horn or concentrator, which mechanically amplifies the vibration to the

required amplitude of 15 – 50 μm and accommodates the tool at its tip.

Schematic view of an Ultrasonic Machine

The ultrasonic vibrations are produced by the transducer.


The transducer for USM works on the following principle

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t USM of brittle work material.

vice, which can be located at the desired position under


ce on the tool during

The horn or concentrator, which mechanically amplifies the vibration to the

ccommodates the tool at its tip.


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• Piezoelectric effect

• Magnetostrictive effect

• Electrostrictive effect

Magnetostrictive transducers are most popular an

Following figure shows a typical magnetostrictive

or concentrator is a wave-guide, which amplifies and concentrates the vibration to the

tool from the transducer.

Figure: Working of horn as mechanical amplifier of amplitude of vibration

The horn or concentrator can be of different shape like

• Tapered or conical

• Exponential

• Stepped

Machining of tapered or stepped horn is much easier as

one.

Following figure shows different horns used in USM

Fig




Piezoelectric effect

Magnetostrictive effect

Electrostrictive effect

Magnetostrictive transducers are most popular and robust amongst all.

shows a typical magnetostrictive transducer along with horn. The horn

guide, which amplifies and concentrates the vibration to the

Working of horn as mechanical amplifier of amplitude of vibration

The horn or concentrator can be of different shape like

Tapered or conical

Machining of tapered or stepped horn is much easier as compared to the exponential

shows different horns used in USM.

Figure: Different Horns used in USM

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transducer along with horn. The horn

guide, which amplifies and concentrates the vibration to the

Working of horn as mechanical amplifier of amplitude of vibration

compared to the exponential

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USM Process:

� The USM process is performed using a desirable tool a

as a media. The cutting tool oscillates at high frequencies (typically 20

� The shape of tool corresponds to the shape requirements

� The abrasive grains are driven by the high speed reciprocations across the small

gap, inbetween the tool and the workpiece.

� Uniform force is used to gradually feed the tool.

� The impact of abrasives is the energy source which is mainly res

removal of material, through the form of small wear particles which are carried

away by the abrasive slurry.

� Due to the abrasive action of

requiring the tool to be made of tough materials.

� Ultrasonic machining is a non

� Following Figure briefly depicts the USM process.

� In ultrasonic machining, a tool of desired shape vibrates at an ultrasonic

frequency (19 ~ 25 kHz) with an amplitude of

workpiece.

� Generally the tool is pressed

� Between the tool and workpiece, the machining zone is flooded with hard

abrasive particles generally in th

� As the tool vibrates over the workpiece, the abrasive particles act as the

indenters and indent both

� The abrasive particles, as they indent, the work material, would remove the

same, particularly if the work material is brittle, due to crack

propagation and brittle fracture of the

� Hence, USM is mainly used for machining brittle materials {which are poor

conductors of electricity and thus cannot be processed by Electrochemical and

Electro-Discharge machining (ECM and ED)}




The USM process is performed using a desirable tool along-with abrasives slurry

as a media. The cutting tool oscillates at high frequencies (typically 20

The shape of tool corresponds to the shape requirements in the workpiece.

The abrasive grains are driven by the high speed reciprocations across the small

gap, inbetween the tool and the workpiece.

Uniform force is used to gradually feed the tool.

The impact of abrasives is the energy source which is mainly responsible in


away by the abrasive slurry.

Due to the abrasive action of particles, gradually wear of the tool occurs, thereby

requiring the tool to be made of tough materials.

ltrasonic machining is a non-traditional machining process.

briefly depicts the USM process.

Figure: The USM process

In ultrasonic machining, a tool of desired shape vibrates at an ultrasonic

frequency (19 ~ 25 kHz) with an amplitude of around 15 – 50 μm over the

Generally the tool is pressed downward with a feed force, F.

Between the tool and workpiece, the machining zone is flooded with hard

abrasive particles generally in the form of a water based slurry.

es over the workpiece, the abrasive particles act as the

indenters and indent both the work material and the tool.

The abrasive particles, as they indent, the work material, would remove the

same, particularly if the work material is brittle, due to crack initiation,

propagation and brittle fracture of the material.

Hence, USM is mainly used for machining brittle materials {which are poor


ischarge machining (ECM and ED)}.

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with abrasives slurry

as a media. The cutting tool oscillates at high frequencies (typically 20-40 kHz)

in the workpiece.

The abrasive grains are driven by the high speed reciprocations across the small

ponsible in


particles, gradually wear of the tool occurs, thereby

In ultrasonic machining, a tool of desired shape vibrates at an ultrasonic

50 μm over the

Between the tool and workpiece, the machining zone is flooded with hard

es over the workpiece, the abrasive particles act as the

The abrasive particles, as they indent, the work material, would remove the

initiation,

Hence, USM is mainly used for machining brittle materials {which are poor


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Mechanism of Material Removal

Although the USM process is commercially used since many decades the exact details of

mechanism leading to the removal of fine materials is still

research works done till date in understanding the

light on some possible mechanisms. Through the investigations and the corresponding

literatures, the main mechanisms responsible for the material removal in USM are as

listed below:

� Mechanical abrasion:

on work piece through the tool.

� Impact: The freely moving particles impact with a certain velocity on the work

piece resulting in micro chipping.

� Erosion: Due to cavitation effect of the abrasive slurry, erosion of th

surface occurs.

� Chemical: Due to fluid employed, chemical effect can come into consideration.

It has been reported in the literature that among the above mentioned mechanisms, the

first two are primarily responsible for major stock removal. The li

erosion plays a lesser role in the removal of material for normal materials, however for

the porous materials; it is observed that erosion due to cavitations is a significant factor.

Advantages of USM

� In USM process, there are no phy

microstructures reveal that there are also no structural changes as the stresses

induced are too less. The cutting forces being low, workpiece is unstressed,

undistorted and free from heat effects.

� There is no direct contact of the tool and workpiece due to the slurry used, it

makes it a wet cutting process. The surfaces produced are free from stress and

damages.

� The process is free from burrs and distortions.

� The process is suitable for any material

� The process is very much suitable for machining brittle materials

� The process offers good surface finish and structural integrity.

Disadvantages / Limitations of USM

� Soft materials like lead and plastics are not

process, since they tend to absorb the abrasive particles rather than to chip

under their impact.

� The USM process consumes higher power and has lower material

compared to traditional fabrication processes.

� The tool wear rate in USM process is fast.

� The areas of machining and higher depths are the constraints in USM.




Mechanism of Material Removal:


mechanism leading to the removal of fine materials is still to be understood. The

works done till date in understanding the process parameters have thrown

possible mechanisms. Through the investigations and the corresponding

mechanisms responsible for the material removal in USM are as

Mechanical abrasion: Occurs due to the hammering effect of abrasive particles

on work piece through the tool.

The freely moving particles impact with a certain velocity on the work

piece resulting in micro chipping.

Due to cavitation effect of the abrasive slurry, erosion of the work

Due to fluid employed, chemical effect can come into consideration.


are primarily responsible for major stock removal. The literature reveals that

lesser role in the removal of material for normal materials, however for

is observed that erosion due to cavitations is a significant factor.

In USM process, there are no physical, chemical or thermal changes. The



undistorted and free from heat effects.

There is no direct contact of the tool and workpiece due to the slurry used, it


The process is free from burrs and distortions.

The process is suitable for any materials, irrespective of electrical conductivity

The process is very much suitable for machining brittle materials

The process offers good surface finish and structural integrity.

Disadvantages / Limitations of USM

Soft materials like lead and plastics are not suitable for machining by the USM


The USM process consumes higher power and has lower material-removal rates

compared to traditional fabrication processes.

e tool wear rate in USM process is fast.

The areas of machining and higher depths are the constraints in USM.

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to be understood. The

process parameters have thrown

possible mechanisms. Through the investigations and the corresponding

mechanisms responsible for the material removal in USM are as

hammering effect of abrasive particles

The freely moving particles impact with a certain velocity on the work

e work

Due to fluid employed, chemical effect can come into consideration.


terature reveals that

lesser role in the removal of material for normal materials, however for

is observed that erosion due to cavitations is a significant factor.

sical, chemical or thermal changes. The



There is no direct contact of the tool and workpiece due to the slurry used, it


s, irrespective of electrical conductivity

suitable for machining by the USM


removal rates

The areas of machining and higher depths are the constraints in USM.

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� As the USM process continuous, the lateral wear of the tool increases gradually

and it tends to make the holes tapered. The sharp corners of the t

rounded off thereby requiring tool replacement essential for producing accurate

blind holes.

� The accuracy of the machined surface gets lost due to setting up of strong lateral

vibrations. This occurs if the axis of the tool and horn, which are braz

are not properly aligned with the transducer axis. In such a case, the tool needs

to be redesigned.

� The holes produced in USM have a tendency to break out at the bottom owing

to the static load and high amplitudes.

� While producing deeper holes

circulation leading to presence of a fewer active grains under the tool face. Due

to this, the bottom surfaces of blind holes tend to become slightly concave.

Applications of USM

� USM process is used in mach

semiconductors, glass, ceramics, carbides etc.

� In machining of advanced ceramics for applications in auto

� In machining, wire drawing, punching or blanking of small dies

� Machining ceramic substrates

sensors used in electronic industries

� Drilling small holes in helicopter power transmission shafts and gears.




As the USM process continuous, the lateral wear of the tool increases gradually

and it tends to make the holes tapered. The sharp corners of the tool get


The accuracy of the machined surface gets lost due to setting up of strong lateral

vibrations. This occurs if the axis of the tool and horn, which are braz


The holes produced in USM have a tendency to break out at the bottom owing

to the static load and high amplitudes.

While producing deeper holes through USM method, there is ineffective slurry


the bottom surfaces of blind holes tend to become slightly concave.

USM process is used in machining hard and brittle metallic alloys,

semiconductors, glass, ceramics, carbides etc.

In machining of advanced ceramics for applications in auto-engine components.

In machining, wire drawing, punching or blanking of small dies

Machining ceramic substrates for drilling holes in borosilicate glass for the

in electronic industries

Drilling small holes in helicopter power transmission shafts and gears.

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As the USM process continuous, the lateral wear of the tool increases gradually

ool get


The accuracy of the machined surface gets lost due to setting up of strong lateral

vibrations. This occurs if the axis of the tool and horn, which are brazed together,


The holes produced in USM have a tendency to break out at the bottom owing

through USM method, there is ineffective slurry


the bottom surfaces of blind holes tend to become slightly concave.

engine components.

for drilling holes in borosilicate glass for the

Drilling small holes in helicopter power transmission shafts and gears.

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Ultrasonic Machine and its Process Parameters

The basic ultrasonic equipment consists of the

� A generator for high frequency oscillations (Ultrasonic generator)

� An acoustic head consisting of transducer and trunk (shank)

� Tool and abrasive slurry elements

The High Frequency Oscillating Current (OC) Generator

� The purpose of the OC generator is to produce high

currents.

� This generator transmits electrical power to the transducer which creates energy

impulses in the ultrasonic range i.e. 18

mechanical vibrations.

� The primary function of the transducer is to convert electrical impulses into

vertical and two dimensional

The Acoustic Head

This is the ‘heart’ of the whole equipment and consists of two parts,

A. The transducer, which converts the high

linear vibrations and

B. The trunk, which mechanically amplifies the linear vibrations.

Ultrasonic transducer

The ultrasonic vibrations are produced by a transduc

generator which gets further powered by an amplifier. The USM transducer works on

the following principle:

� Piezo-electric effect4

� Magneto-strictive effect

� Electro-strictive effect

The function of ultrasonic transducer is to converts high frequency electrical impulses

from the oscillator into mechanical vibrations. The

periodically shortens and lengthens.

For low power applications piezo

applications magneto-strictive

The trunk

It is a critical link in the ultrasonic machining system.

It is known by several names such

44 Piezo-Electric Effect: Electricity produced by mechanical pressure on certain crystals (notably quartz or

Rochelle salt); alternatively, electrostatic stress produces a change in the linear dimensions of the crystal





The basic ultrasonic equipment consists of the following elements:

A generator for high frequency oscillations (Ultrasonic generator)

An acoustic head consisting of transducer and trunk (shank)

Tool and abrasive slurry elements

The High Frequency Oscillating Current (OC) Generator:

The purpose of the OC generator is to produce high frequency oscillating

generator transmits electrical power to the transducer which creates energy

the ultrasonic range i.e. 18-20 KHz and converts them into

vibrations.

primary function of the transducer is to convert electrical impulses into

dimensional strokes.

This is the ‘heart’ of the whole equipment and consists of two parts,

The transducer, which converts the high frequency output of the generator

The trunk, which mechanically amplifies the linear vibrations.

The ultrasonic vibrations are produced by a transducer that is driven by the signal

ther powered by an amplifier. The USM transducer works on

strictive effect

strictive effect


from the oscillator into mechanical vibrations. The periodicity of these vibrations

periodically shortens and lengthens.

piezo-electric transducers are used, whereas for

strictive transducers are commonly used.

he ultrasonic machining system.

is known by several names such as shank, horn, concentrator and amplifier.

Electricity produced by mechanical pressure on certain crystals (notably quartz or

alternatively, electrostatic stress produces a change in the linear dimensions of the crystal

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frequency oscillating

generator transmits electrical power to the transducer which creates energy

hem into

primary function of the transducer is to convert electrical impulses into

frequency output of the generator into

er that is driven by the signal

ther powered by an amplifier. The USM transducer works on


periodicity of these vibrations

are used, whereas for high power

as shank, horn, concentrator and amplifier.

Electricity produced by mechanical pressure on certain crystals (notably quartz or

alternatively, electrostatic stress produces a change in the linear dimensions of the crystal.

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The trunk amplifies and focuses vibrations of

necessary enough for driving the

The increase in amplitude of vibrations at the tool end is

section of the trunk.

The Tool

The tool is designed to provide the maximum amplitude

selection of tool material is very important as the tool tip i

must not fail due to wear.

The commonly used tool materials are brass, high speed

stainless steel, tungsten carbide and monel

silver brazing or by hard soldering. At times it is fastened (screwed) with

The Abrasive Slurry

The recommended slurry to be used in this process is a mi

liquid (water or kerosene). The slurry is pumped across the tool

part of the machine-system. The properties requir

abrasives include low viscosity, good wetting and high t

recommended medium for abrasive transportation which generally m

process requirement.

Process Parameters in USM

The determination of accurate process parameters which a

ultrasonic machining is hard to determine as i

The geometry and material properties of the work piece and tool make the system

further complex to ascertain its performance characteristics.

However, the performance of ultrasonic

machining rate, machining accuracy, surface

parameters which can affect the performance of USM

four major groups. In order to identify the process

qualities of the machined surface, an Ishikawa cause

is constructed.

5 Monel: An alloy of nickel and copper and other metals (such as iron and/or manganese and/or

aluminium).




ifies and focuses vibrations of the transducer to the required intensity

necessary enough for driving the tool.

increase in amplitude of vibrations at the tool end is obtained by reducing the cross

The tool is designed to provide the maximum amplitude of vibration at the free end. The

selection of tool material is very important as the tool tip is subjected to vibration and it

materials are brass, high speed steel, mild-steel, silver,

tungsten carbide and monel5. The tool is attached to the trunk (horn) by

silver brazing or by hard soldering. At times it is fastened (screwed) with the trunk.

The recommended slurry to be used in this process is a mixture of abrasive particles and

liquid (water or kerosene). The slurry is pumped across the tool face. Slurry pump is a

system. The properties required from the transport medium of

abrasives include low viscosity, good wetting and high thermal conductivity. Water is a

recommended medium for abrasive transportation which generally meets most of the

The determination of accurate process parameters which affect performance of

ng is hard to determine as it works under multiple factors.

material properties of the work piece and tool make the system

ascertain its performance characteristics.

However, the performance of ultrasonic machining, to some extent is decided by the

machining rate, machining accuracy, surface finish and tool wear. The process

parameters which can affect the performance of USM are arranged into the following

four major groups. In order to identify the process parameters in USM affecting the

qualities of the machined surface, an Ishikawa cause – effect diagram as shown in Fig

: An alloy of nickel and copper and other metals (such as iron and/or manganese and/or

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the transducer to the required intensity

obtained by reducing the cross

of vibration at the free end. The

s subjected to vibration and it

steel, silver,

trunk (horn) by

the trunk.

particles and

face. Slurry pump is a

ed from the transport medium of

hermal conductivity. Water is a

eets most of the

ffect performance of

t works under multiple factors.

material properties of the work piece and tool make the system

some extent is decided by the

finish and tool wear. The process

are arranged into the following

USM affecting the

ffect diagram as shown in Fig.1

: An alloy of nickel and copper and other metals (such as iron and/or manganese and/or

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Figure 1: Ishikawa Cause and effect diagram showing Performance in USM

The process parameters which govern the ultrasonic

identified and the same are listed below

• Amplitude of vibration (a

• Frequency of vibration (f)

• Feed force (F) – related to tool dimensions

• Feed pressure (p)

• Abrasive size –

• Abrasive material

• Flow strength of work material

• Flow strength of the tool material

• Contact area of the tool

• Volume concentration of abrasive in water slurry




kawa Cause and effect diagram showing Performance in USM

The process parameters which govern the ultrasonic machining process have been

identified and the same are listed below along with material parameters:

• Amplitude of vibration (ao) – 15 – 50 μm

• Frequency of vibration (f) – 19 – 25 kHz

related to tool dimensions

15 μm – 150 μm

- Al2O3

- SiC

- B4C

- Boronsilicarbide

- Diamond

• Flow strength of work material

• Flow strength of the tool material

• Contact area of the tool – A

• Volume concentration of abrasive in water slurry – C

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machining process have been

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Figure 2: Effect of machining parameters on MRR

Machine Parameters

These are those parameters w

They include frequency and amplitude of the ultrasonic vibrations,

piece rotation and tool-head




Effect of machining parameters on MRR

These are those parameters which can be set on the machine.

amplitude of the ultrasonic vibrations, the static load, work

rotation.

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the static load, work

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Abrasive Slurry Characteristics

The type and size of the abrasives particles, its hardne

carrier to form the abrasive slurry and the concentration of abrasive pa

slurry.

Work piece properties

The hardness, fracture characteristics, strength, work

properties of the work material also affect the process performance.

Tool Material Properties and Tool Geometry

The shape of the tool (solid or hollow), mechanical properties of the ma

tool-making are some of the other parameters

performance.

Rotary Ultrasonic Machining (RUM)

If the ultrasonic machining equipment possesses

ultrasonic head or at the worktable for drilling, milling, an

is termed as Rotary Ultrasonic Machine (RUM). In

combination of rotational motion and axial vibrations (of

the tool and the work piece material, provides uniform tool wear, a high degree of hole

roundness and rapid removal of material from the cutting zone.




Abrasive Slurry Characteristics

The type and size of the abrasives particles, its hardness, type of the fluid used as a

carrier to form the abrasive slurry and the concentration of abrasive particles in the

The hardness, fracture characteristics, strength, work hardening tendency and fatigue

properties of the work material also affect the process performance.

Tool Material Properties and Tool Geometry

of the tool (solid or hollow), mechanical properties of the material used in

making are some of the other parameters that may affect the USM process

Rotary Ultrasonic Machining (RUM)

If the ultrasonic machining equipment possesses a rotary movement either at the

ultrasonic head or at the worktable for drilling, milling, and threading operations, then it

is termed as Rotary Ultrasonic Machine (RUM). In rotary ultrasonic machines the

combination of rotational motion and axial vibrations (of tool) reduce friction betwee

tool and the work piece material, provides uniform tool wear, a high degree of hole

and rapid removal of material from the cutting zone.

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ss, type of the fluid used as a

rticles in the

hardening tendency and fatigue

terial used in

that may affect the USM process

ry movement either at the

d threading operations, then it

rotary ultrasonic machines the

tool) reduce friction between

tool and the work piece material, provides uniform tool wear, a high degree of hole

Ultrasonic machining (Usm)

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