NON-TRADITIONAL MACHINING
Sub Code: 21ME751
Module -2
Ultrasonic Machining(USM)
Principal of USM
Ultrasonic machining process is a type of non traditional
machining process in which the slurry of small abrasive particles
are forced against the work piece by means of vibrating tool and
it causes the removal of metal from the work piece in the form of
extremely small chips.
Working of USM
Working of USM
Working of USM
USM Equipment
Ultrasonic Machining comprises several essential parts that work
harmoniously to achieve precise material removal:
1) Power Supply: The power supply, also known as a high-frequency
generator or electronic oscillator, converts a standard electrical supply into a high-
frequency electrical supply, typically ranging from 20-40 kHz. The electrical signal is
then supplied to the transducer.
2) Electro-Mechanical Transducer: The transducer converts
electrical energy into mechanical vibrations, transmitting high-frequency signals with
low amplitude to the tool. Two types of transducers are used: piezoelectric transducers
and magnetostrictive transducers. The transducer with magnetostrictive effect is mostly
utilized in ultrasonic machining process.
3) Transducer Cone or horn:
The transducer cone or horn, amplifies and focuses the vibration of the transducer to an
intensity suitable for driving the tool during cutting operations. It is made of hard, non-
magnetic, and easily machinable materials like K-Monel, metal bronze, or mild steel.
4) Tool:
The tool, made of a ductile material, undergoes hammering or percussion using
abrasive particles to remove material from the work piece. Tool wear and fatigue
resistance are crucial, as ultrasonic frequencies increase the hammering rate to enhance
material removal.
5) Abrasive Slurry:
A slurry of abrasive particles is applied between the tool and work piece to facilitate
material removal. The abrasives, such as boron carbide or silicon carbide, are rigid and
hard, ensuring efficient machining. Fresh abrasives are continuously supplied through a
water jet to maintain optimal machining efficiency.
Tool feed Mechanism in USM
In USM the tool feed mechanism must perform the following
functions:
Bring the tool very slowely, close to work piece
Apply the static load between the tool and the work piece during
mechanism.
Decrease the force at a specified depth
Withdraw the tool after machining is completed.
The various feed mechanism available in USM are as follows:
1. Gravity feed mechanism
2. Spring loaded feed mechanism
3. Pneumatic or hydraulic feed mechanism
4. Motor controlled feed mechanism.
1) Gravity feed Mechanism:
In this mechanism counter balance weights are used to apply the required
load to the head through pulley and rope arrangement. In order to reduce
friction ball, bearings are used. Gravity feed mechanisms are simple in
construction, but this mechanism is insensitive and inconvenient to adjust.
2) Spring loaded feed mechanism:
In this mechanism spring pressure is used to feed the tool during
the machining operation. This type of mechanism is quite
sensitive and easy to adjust.
3) Pneumatic or hydraulic feed mechanism
In this mechanism, hydraulic cylinder is used to give a linear
motion of the tool. High feed rate and accurate positioning are
possible with hydraulic feed mechanism.
Process Parameters of USM
The following parameters which affect the material removal
rate(MRR),surface finish and accuracy of the machined surface.
1. Amplitude and frequency of vibrations of the tool
2. Slurry (Abrassive - water mixture)
3. Tool and work material
4. Type of Abrassive
5. Abrasive size
6. Effect of applied static load
1) Amplitude and frequency of vibrations of the tool
2) Slurry (Abrassive - water mixture)
3) Tool and work material
4) Type of Abrassive
The abrassive used should be harder than the work piece material being
machined, else life time of the abrassive will be substantially shortened
resulting in poor surface finish during subsequent machining . Boron
carbide is used for high metal removal rate and also for hard work piece
materials like tungsten, tool steel and precious stones.
5) Abrasive size
6) Effect of applied static load
Process Characteristics of USM
Following are a few process characteristics or
capabilities of USM
1. Metal Removal Rate (MRR)
2. Surface Finish
3. Accuracy
4. Drilling hole capacity
1) Metal Removal Rate (MRR)
2) Surface Finish
3) Accuracy
4) Drilling hole capacity
Advantages of USM
1. This process is used for drilling both circular and non-
circular holes in very hard materials like carbide, ceramics,
etc.
2. This process is best suited for brittle materials.
3. The machining operation is simple and requires less time.
4. This process is economical.
5. Glass, Ceramic, and tungsten can be machined.
6. A semi-skilled operator can operate the machine.
7. Better efficiency can be achieved.
8. Good surface finish.
9. It is suitable for both conducting and non-conducting
materials.
10. High accuracy can be achieved
Limitations of USM
1. Low material cutting rate.
2. High power consumption.
3. Low penetration rate.
4. The process is limited to the machined surface of a
small size.
5. Shorter tool life.
6. Not suitable for soft work piece materials
7. Process become costly for complex shape s and hard
materials
8. Tool wear is more
Applications of USM
1. Cutting of semiconductor materials for electronic
applications.
2. Drilling the round holes of any shape.
3. Grinding the brittle materials.
4. Slicing and broaching hard materials.
5. Machining the glasses, and ceramics.
6. Machining the precise mineral stones, tungsten.
7. Piercing of dies and for parting off operation.
8. This is precise enough to be used in the creation of
micro-electro-mechanical system components such
as micro-structured glass wafers