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Mech-Ultrasonic Machining

The document discusses ultrasonic machining (USM), a non-traditional mechanical process that uses high-frequency vibrations and abrasive slurry to uniformly remove material, even from hard and brittle substances. USM involves a tool that oscillates at 20-40 kHz while submerged in abrasive particles, which are driven by the vibrations to erode small amounts of material from the workpiece. Key components of a USM system include a transducer to generate ultrasonic vibrations, a tool and holder, and an abrasive slurry. Process parameters like vibration amplitude and frequency, feed force, and abrasive size influence the results. USM is useful for drilling small holes and can machine materials that

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83 views20 pages

Mech-Ultrasonic Machining

The document discusses ultrasonic machining (USM), a non-traditional mechanical process that uses high-frequency vibrations and abrasive slurry to uniformly remove material, even from hard and brittle substances. USM involves a tool that oscillates at 20-40 kHz while submerged in abrasive particles, which are driven by the vibrations to erode small amounts of material from the workpiece. Key components of a USM system include a transducer to generate ultrasonic vibrations, a tool and holder, and an abrasive slurry. Process parameters like vibration amplitude and frequency, feed force, and abrasive size influence the results. USM is useful for drilling small holes and can machine materials that

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www.studymafia.

org
SEMINAR
ON
ULTRASONIC MACHINING

Submitted To: Submitted By:


www.studymafia.org www.studymafia.org
Content
1. Introduction
2. Schematic diagram
3. Principle & Working
4. Mechanism
5. USM system & subsystem
6. Process parameter & effect
7. Application
8. Advantages & disadvantages
9. References
Ultrasonic Machining- Introduction

 Ultrasonic machining is a non-


traditional mechanical means of
uniform stock material removal
process
 It is applicable to both
conductive and nonconductive
materials.
 Particularly suited for very
hard and/or brittle materials
such as graphite, glass, carbide,
and ceramics.
Ultrasonic Machining
 It is a mechanical material
removal process, used to
erode material in the form of
fine holes and cavities in hard
or brittle workpiece.
 It uses formed tools,
vibrations of high frequency
and a suitable abrasive slurry
mix.
 Ultrasonic range is possible
with the help of piezoelectric
materials.
 Frequency > 20,000 Hz.
Schematic Diagram
5
Process

 Impact erosion process - abrasive


particles.
 Cutting abrasive particles in the

slurry (fluid).
 Material removal abrading action

“shaped tool” and the workpiece.


Working Principle
 The process is performed by a
cutting tool, which oscillates at high
frequency, typically 20-40 kHz, in
abrasive slurry.
 The tool is gradually fed with a
uniform force.
 The high-speed reciprocations of the
tool drive the abrasive grains across
a small gap against the workpiece .
 The impact of the abrasive is the
energy principally responsible for
material removal in the form of small
wear particles that are carried away
by the abrasive slurry.
 The shape of the tool corresponds to
the shape to be produced in the
workpiece. Mohit Ostwal, Asst. Prof., JIET-coed, Jodhpur
Mechanism for material removal
 Occurs when the abrasive particles, suspended in the slurry
between the tool and workpiece, are struck by the downstroke
of the vibration tool.
 The impact propels the particles across the cutting gap,
hammering them into the surface of both tool and workpiece.
Collapse of the cavitation bubbles in the abrasive suspension
results in very high local pressures.
 Under the action of the associated shock waves on the abrasive
particles, microcracks are generated at the interface of the
workpiece – brittle fracture.
 The brittle fracture lead to chipping of particles from the
workpiece.
USM system components

1. Power supply
2. Transducer
3. Tool holder
4. Tool
5. Abrasive slurry

Mohit Ostwal, Asst. Prof., JIET-coed, Jodhpur 06/24/2021


USM system components

1. Transducer

 Piezoelectric transducers utilize crystals like quartz


whose dimensions alter when being subjected to
electrostatic fields.

 The charge is directionally proportional to the


applied voltage.

 To obtain high amplitude vibrations the length of


the crystal must be matched to the frequency of the
generatorMohit
which produces
Ostwal, resonant
Asst. Prof., JIET-coed, Jodhpurconditions.
06/24/2021
USM system component
2. Abrasive
 Abrasive Slurry
- common types of abrasive
- Boron carbide (B4C) good in general, but expensive
- Silicon carbide (SiC) glass, germanium, ceramics
- Corundum (Al2O3)
- Diamond (used for rubies , etc)
- Boron silicon-carbide (10% more abrasive than B4C)
 Liquid
- Water most common
- Benzene
- Glycerol
- Oils
- High viscosity decreases MRR
USM system component
3. Tool Holder/Acoustic head

 The shape of the tool holder is cylindrical or conical, or a


modified cone which helps in magnifying the tool tip
vibrations.
 Its function is to increase the tool vibration amplitude and
to match the vibrator to the acoustic load. Therefore it
must be constructed of a material with good acoustic
properties and be highly resistant to fatigue cracking.
 Monel and titanium have good acoustic properties and are
often used together with stainless steel, which is cheaper.
Exponential tapered stepped
06/24/2021
USM system component
4. Tool

 Tool material should be tough and ductile. Low carbon steels and stainless steels give
good performance.

 Tools are usually 25 mm long ; its size is equal to the hole size minus twice the size of
abrasives.

 Mass of tool should be minimum possible so that it does not absorb the ultrasonic energy.

 It is important to realize that finishing or polishing operations on the tools are sometimes
necessary because their surface finish will be reproduced in the workpiece.

 Tool and toolholder are often attached by silver brazing.


Process Parameters
1. Amplitude of vibration (a) - 15- 50 um.
2. Frequency of vibration (f)-19-25kHz
3. Feed force (F)
4. Feed pressure (p)
5. Abrasive size-15-150um
6. Contact area of the tool – A
7. Volume concentration of abrasive in slurry - C
Process Parameters

Mohit Ostwal, Asst. Prof., JIET-coed, Jodhpur 06/24/2021


Application
It is mainly used for
(1) drilling
(2) grinding,
(3) Profiling
(4) coining
(5) piercing of dies
(6) welding operations on all materials which can be treated
suitably by abrasives.
(7) Used for machining hard and brittle metallic alloys,
semiconductors, glass, ceramics, carbides etc.
(8) Used for machining round, square, irregular shaped holes and surface
impressions.
Advantages
 Machining any materials regardless of their conductivity

 USM apply to machining semi-conductor such as silicon,


germanium etc.

 USM is suitable to precise machining brittle material.

 USM does not produce electric, thermal, chemical abnormal


surface.

 Can drill circular or non-circular holes in very hard materials

 Less stress because of its non-thermal characteristics


Disadvantages
 USM has low material removal rate. (3-15mm3/min)

 Tool wears fast in USM.

 Machining area and depth is restraint in USM.


References
19

 Google.com
 Wikipedia.org
 Studymafia.org
 Pptplanet.com

Mohit Ostwal, Asst. Prof., JIET-coed, Jodhpur 06/24/2021


Thanks

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