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Ultrasonic Machining (USM) - Detailed Explanation

Ultrasonic Machining (USM) is a non-traditional machining process that utilizes high-frequency vibrations and an abrasive slurry to remove material from hard and brittle materials like glass and ceramics. The process involves a vibrating tool, abrasive particles, and a feeding mechanism, ensuring precise machining without thermal damage. While USM offers advantages such as no tool wear and high precision, it is limited by its slow speed and high tooling costs.

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47 views3 pages

Ultrasonic Machining (USM) - Detailed Explanation

Ultrasonic Machining (USM) is a non-traditional machining process that utilizes high-frequency vibrations and an abrasive slurry to remove material from hard and brittle materials like glass and ceramics. The process involves a vibrating tool, abrasive particles, and a feeding mechanism, ensuring precise machining without thermal damage. While USM offers advantages such as no tool wear and high precision, it is limited by its slow speed and high tooling costs.

Uploaded by

fadil1642005
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Ultrasonic Machining (USM) – Detailed Explanation

Ultrasonic Machining (USM) is a non-traditional machining process that removes material


by using high-frequency vibrations along with an abrasive slurry. It is particularly useful
for hard and brittle materials like glass, ceramics, and diamonds.

1. Principle of Ultrasonic Machining (USM)


●​ A tool vibrates at ultrasonic frequencies (20 kHz – 40 kHz).
●​ Abrasive particles in the slurry impact the workpiece.
●​ The mechanical erosion process gradually removes material.

Working Mechanism

1.​ A vibrating tool (attached to a transducer) moves up and down.


2.​ Abrasive slurry (mixture of water and abrasive particles) is continuously supplied.
3.​ The abrasives strike the workpiece, causing tiny fractures and material removal.

2. Components of USM
1. Ultrasonic Generator

●​ Converts electrical energy into high-frequency signals (~20-40 kHz).


●​ Sends signals to the transducer.

2. Transducer

●​ Converts electrical energy into mechanical vibrations.


●​ Common types:
○​ Piezoelectric transducer – Uses quartz crystals.
○​ Magnetostrictive transducer – Uses magnetic materials.

3. Tool Holder & Tool

●​ Holds the tool and transfers vibrations to the workpiece.


●​ Made of soft metals like brass or stainless steel.

4. Abrasive Slurry

●​ Mixture of water + abrasive particles (Silicon carbide, Alumina, or Boron carbide).


●​ Carries away the removed material.
5. Workpiece

●​ Usually hard and brittle materials like glass, ceramics, or tungsten carbide.

6. Feeding Mechanism

●​ Ensures continuous downward feed of the tool onto the workpiece.

3. Diagram of Ultrasonic Machining


Below is a simplified diagram of USM:

┌──────────────────┐
│ Ultrasonic │
│ Generator │
└──────────────────┘
│
▼
┌──────────────────┐
│ Transducer │ → Converts electrical signals into
vibrations
└──────────────────┘
│
▼
┌──────────────────┐
│ Tool Holder & │
│ Tool (Brass, SS) │ → Vibrates at high frequency
└──────────────────┘
│
▼
~~~~~~~~~~~~~~~
| Abrasive Slurry | → Contains fine abrasive particles
~~~~~~~~~~~~~~~
│
▼
┌──────────────────┐
│ Workpiece │ → Brittle materials (glass, ceramics)
└──────────────────┘
4. Process of Ultrasonic Machining
1.​ Power supply energizes the ultrasonic generator.
2.​ The transducer converts electrical signals into vibrations.
3.​ Vibrations are transferred to the tool.
4.​ Abrasive slurry is fed into the machining gap.
5.​ Abrasive particles impact the workpiece, gradually removing material.
6.​ Material is removed as tiny fractures, carried away by the slurry.
7.​ Final shape is formed after repeated impacts.

5. Applications of USM
●​ Drilling micro-holes in glass, ceramics, and semiconductors.
●​ Shaping hard metals like tungsten carbide.
●​ Engraving delicate patterns in brittle materials.
●​ Creating surgical instruments and precision components.

6. Advantages of USM
✔️ No heat generation → No thermal damage to workpiece.​
✔️ Works on hard materials like glass and ceramics.​
✔️ Precise machining → Produces fine and accurate shapes.​
✔️ No tool wear → Tool does not directly touch the workpiece.

7. Disadvantages of USM
❌ Slow process → Not suitable for high-volume production.​
❌ Limited to brittle materials → Cannot machine soft metals efficiently.​
❌ High tool cost → Special tooling required.

Conclusion
USM is a highly effective machining process for brittle and hard materials, ensuring
high precision without thermal damage. However, its slow material removal rate makes
it unsuitable for mass production.

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