A

SEMINAR REPORT

On

ULTRASONIC MACHINING (USM)

Submitted in partial fulfillment of the
Requirement for the award of the degree
of
BACHOLER OF TECHNOLOGY
in

Mechanical Engineering

By

CHANDRA KANT SAURABH

DEPARTMENT OF MECHANICAL ENGINEERING

RAJKIYA ENGINEERING COLLEGE, BANDA
Affiliated to
DR. A.P.J. ABDUL KALAM TECHNICAL UNIVERSITY
(Formerly Uttar Pradesh Technical University)
LUCKNOW
NOVEMBER 2017

[i]
 DEPARTMENT OF MECHANICAL ENGINEERING
RAJKIYA ENGINEERING COLLEGE, BANDA

CANDIDATE’S DECLARATION
I hereby declare that the work which is presented in this seminar, entitled, “ULTRASONIC
MACHINING (USM)”, submitted in partial fulfillment of the requirement for the award of
the degree of Bacholer of Technology in Department of Mechanical engineering Rajkiya
Engineering College, Banda affiliated to Uttar Pradesh Technical University (formerly
Gautam Buddh Technical University) Lucknow is an authentic record of my own work carried
out during the period from August 2017 to November 2017 under the supervision and guidance
of Er. Akshendra Soni, Rajkiya Engineering College, Banda. I also declare that I have not
submitted the matter embodied in this seminar for award of any other degree.

Date:
Place: (CHANDRA KANT SAURABH)

[ii]
 CERTIFICATE

Certified that CHANDRA KANT SAURABH (1673440902) has carried out the seminar
Work presented in this entitled “ULTRASONIC MACHINING (USM)” for the award of
Bachelor of Technology from RAJKIYA ENGINEERING COLLEGE, BANDA under my
supervision.

(Er. Shrinkhla kanojiya ) (Er. Akshendra Soni)

Seminar coordinator, Under Guidance
Department of Mechanical Engineering,
Rajkiya engineering college, Banda
Atarra, Banda-210201

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 ACKNOWLEDGMENTS

I would like to thank my parents for the encouragement and support they showed during this
work for which just expressing a work of thanks would not be sufficient.

This seminar would not have been possible without help and support of my supervisor Er.
Akshendra Soni who has always been up with valuable suggestions in completing this work.

I would like to thanks Er. Shrinkhla Kanojiya for his helpful attitude, cooperation and
encouragement without which this work would have not been possible.

I also thanks to all staff members of the Mechanical Engineering Department for their helps
rendered

Date:

Place: (CHANDRA KANT SAURABH)

[iv]
 ABSTRACT

A model is proposed for the mechanism of material removal in ultrasonic machining. An

analysis of material removal in ultrasonic machining due to (a)direct impact of tool on the
abrasive grains in contact with the workpiece and tool, and (b)impact of grains accelerated by
the vibrating tool is presented. From this model and fundamental physical principles, material
removal rate is derived.

[v]
 CONTENTS

Particulars Page. No.

CERTIFICATE I
ACKNOWLEDGE Ii
ABSTRACT Iii
CONTENT Iv

CHAPTER 1 INTRODUCTION 1-6

1.1 INTRODUCTION 1

1.2 HOSTORY 2

1.3 WHAT IS USM 2

1.4 PRINCIPLE 3

1.5 MATERIAL REMOVAL MODEL IN USM 3

1.6 USM SYSTEM COMPONENT 4

CHAPTER 2 WORKING 7-13

2.1 WORKING 7

2.2 PROCESS PARAMETERS 8

2.3 MATERIAL REMOVING RATE 9

2.4 FACTOR AFFECTING MRR 9

2.5 SURFATCE QUALITY 11

2.6 APPLICATION 12

2.7 ADVANTAGES 12

2.8 DISADVANTAGES 13

CHAPTER 3 CONCLUSION AND RECOMMENDATION 14

CONCLUSION AND RECOMMENDATION 14

REFERENCES 15

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 CHAPTER 1

INTRODUCTION

1.1 INTRODUCTION
Ultrasonic machining is used for machining hard materials and brittle materials.Ultrasonic
machining (USM) is the removal of material by the abrading action of grit-loaded liquid slurry
circulating between the workpiece and a tool vibrating perpendicular to the workface at a
frequency above the audible range.The workpiece is placed under the face of the tool which is
subjected to high frequency vibration perpendicular to the surface being machined. Abrasive
slurry is conveyed to the working zone between the face of the tool and the surface being
machined. The tool moves towards the workpiece and is subjected to a static driving force.
Repetitive impact of the tool on the grains of the abrasive material lead to the fracture of the
workpiece material and to the creation of a cavity with the shape mirror formed of the tool. The
abrasive particles are propelled or hammered against the workpiece by the transmitted
vibrations of the tool. The particles then microscopically erode the workpiece.

 In ultrasonic machining (USM), also called ultrasonic grinding, high-frequency

vibrations delivered to a tool tip, embedded in abrasive slurry, by a booster or
sonotrode, create accurate cavities of virtually any shape; that are, “negatives” of the
tool.

 Since this method is non-thermal, non-electrical, and non-chemical, it produces

virtually stress-free shapes even in hard and brittle work-pieces. Ultrasonic drilling is
most effective for hard and brittle materials; soft materials absorb too much sound
energy and make the process less efficient.

 Almost any hard and brittle material, including aluminum oxides, silicon, silicon
carbide, silicon nitride, glass, quartz, sapphire, ferrite, fiber optics, etc., can be
ultrasonically machined.

 The tool does not exert any pressure on the work-piece (drilling without drills),
and is often made from a softer material than the work-piece, say from brass, cold-
rolled steel, or stainless steel and wears only slightly.

[1]
  The roots of ultrasonic technology can be traced back to research on the
piezoelectric effect conducted by Pierre Curie around 1880. He found that
asymmetrical crystals such as quartz and Rochelle salt (potassium sodium titrate)
generate an electric charge when mechanical pressure is applied. Conversely,
mechanical vibrations are obtained by applying electrical oscillations to the same
crystals. Ultrasonic waves are sound waves of frequency higher than 20,000 Hz.

1.2 HISTORY
• The roots of ultrasonic technology can be traced back to research on the piezoelectric
effect conducted by Pierre Curie around 1880.

• He found that asymmetrical crystals such as quartz and Rochelle salt (potassium
sodium titrate) generate an electric charge when mechanical pressure is applied.

• Conversely, mechanical vibrations are obtained by applying electrical oscillations to

the same crystals.

• One of the first applications for Ultrasonic was sonar (an acronym for sound navigation
ranging). It was employed on a large scale by the U.S. Navy during World War II to
detect enemy submarines.

• Today's Ultrasonic applications include medical imaging (scanning the unborn fetus)
and testing for cracks in airplane construction.

1.3 WHAT IS USM ?

Ultrasonic machining is a nontraditional process. In this process abrasives contained in the
slurry are driven against the work by a tool oscillating at low amplitude (25–100 microns) and
high frequency (15–30 kHz). Ultrasonic refers to waves of high frequency above the audible
range of 20 kHz. The ultrasonic machining was proposed by L Balamuth in 1945. It was
developed for finishing of electro spark machine parts. The USM process consists of tool made
of ductile and tough material. Tool oscillates with high frequency, and the continuous abrasive

[2]
slurry is fed between the tool and workpiece. The impact of the hard abrasive particles fractures
the workpiece thus removing the small particles from the work surface.

1.4 PRINCIPLE
 The machining zone (between the tool and the work piece) is flooded with hard
abrasive particles generally in the form of water based slurry.
 As the tool vibrates over the work piece, abrasive particles acts as indenter and
indent both work and tool material .
 Abrasive particles , as they indent , the work material would remove the
material from both tool and work piece.
 In Ultrasonic machining material removal is due to crack initiation, propagation and
brittle fracture of material.

1.5 Material Removal Models in USM

The following are the Material Removal Models used in USM

1. Throwing of abrasive grains.

2. Hammering of abrasive grains.
3. Cavitations in the fluid medium arising out of ultrasonic vibration of tool.
4. Chemical erosion due to micro –agitations.

Effect of Slurry, Tool and Work Material

 MRR increases with slurry concentration.
 Slurry saturation occurs at 30 to 40% abrasive/water mixture.
 Material Removal rate drops with increasing viscosity.
 The pressure with which the slurry is fed into the cutting zone affects MRR .
 In some cases MRR can be increased even ten times by supplying the slurry at
increased pressure.
 The shape of the tool affects the MRR. Narrower rectangular tool gives more MRR
compared to square cross section.

[3]
  Conical tool gives twice MRR compared to cylindrical tool.
 The brittle behavior of material is important in determining the MRR.
 Brittle material can be cut at higher rates than ductile materials.

TRANSDUCER
 The high frequency electrical signal is transmitted to traducer which converts
it into high frequency low amplitude vibration.

 Essentially transducer converts electrical energy to mechanical vibration. There

are two types of transducer used

1. Piezo electric transducer

2. Magneto-stricitve transducer.

MAGNETOSTRICTIVE TRANSDUCER

 These transducer are made of nickel , nickel alloy sheets.

 Their conversion efficiency is about 20-30%.
 Such transducers are available up to 2000 Watts.
 The maximum change in length can be achieved is about 25 microns.

1.6 USM system components

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

[4]
 (Source: [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 generator which produces resonant conditions.

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)

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- Boron silicon-carbide (10% more abrasive than B4C)

 Liquid
- Water most common
- Benzene
- Glycerol
- Oils
- High viscosity decreases MRR

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.

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.

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 CHAPTER 2
WORKING

2.1 WORKING

(Source: [1])
Steps of Working :
1. A.C. power supply is fed in to the U.S. waves generator which converts low frequency
(50 Hz) electrical power to high frequency (20 KHz) electrical power.
2. This high frequency electrical signal is transmitted to the ultrasonic transducer which
converts it in to high frequency low amplitude vibrations.
3. These high frequency vibrations are transmitted to the tool via tool holder.
4. The tool shape is made converse to the desired cavity. The tool is placed very near to
the work surface and the gap between the vibrating tool and the work piece is flooded
with the abrasive slurry made up of fine abrasive particles and suspension medium
(Usually water).
5. As the tool vibrates in its downward stroke, it strikes the abrasive particles. This impact
from the tool propels the grains across the gap between the tool and the work particles
attains K.E. and attains the work surface with a force greater than their own weight.
6. This force is sufficient to remove material from the brittle work piece (like carbide,
glass, ceramic, silicon, titanium, tungsten etc.) and results in a crater on it.

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2.2 PROCESS PARAMETERS
1. Various parameters that affect the ultrasonic machining are:
2. Amplitude of vibration ( 15 to 50 microns)
3. Frequency of vibration (19 to 25 kHz)
4. Feed force (F) related to tool dimensions
5. Feed pressure
6. Abrasive size
7. Abrasive material: Al2O3, SiC, B4C, boron silica carbide, diamond
8. Flow strength of the work material
9. Flow strength of the tool material
10. Contact area of the tool
11. Volume concentration of abrasive in water slurry
12. Tool
(a) Material of tool
(b) Shape
(c) Amplitude of vibration
(d) Frequency of vibration
(e) Strength developed in tool
(g) Gap between tool and work
13. Work material
(a) Material
(b) Impact strength
(c) Surface fatigue strength
14. Slurry
(a) Abrasive—hardness, size, shape and quantity of abrasive flow
(b) Liquid—chemical property, viscosity, flow rate
(c) Pressure
(d) Density

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 2.3 Material Removal Rate
TABLE 1

2.4 Factors affecting MRR

1. Tool Oscillation or Vibration – Amplitude & Frequency
• Amplitude of the tool oscillation has the greatest effect of all the process variables.
• MRR increases with a rise in the tool vibration amplitude.
• Vibration amplitude determines the velocity of the abrasive particles at the interface
between the tool and workpiece.
• Under such circumstances the kinetic energy rises, at larger amplitudes, which enhances
the mechanical chipping action and consequently increases the MRR.
• A greater vibration amplitude may lead to the occurrence of splashing, which causes a
reduction of the number of active abrasive grains and results in a decrease in the MRR.
• According to Kaczmarek (1976) with regard to the range of grain sizes used in practice,
the amplitude of oscillation varies within the limits of 0.04 to 0.08 mm.

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 • The increase of feed force induces greater chipping forces by each grain, which raises
the overall removal rate.
• McGeough (1988) reported that the increase in vibration frequency reduces the removal
rate.
• This trend may be related to the small chipping time allowed for each grain such that a
lower chipping action prevails and causing a decrease in the removal rate.

2. Abrasive Grains
• Both the grain size and the vibration amplitude have a similar effect on the removal
rate.
• According to McGeough (1988), MRR rises at greater grain sizes until the size reaches
the vibration amplitude, at which stage, the MRR decreases.
• When the grain size is large compared to the vibration amplitude, there is a difficulty
of abrasive renewal.
• Because of its higher hardness, B4C achieves higher removal rates than silicon carbide
(SiC) when machining glass.
• The MRR obtained with silicon carbide is about 15 % lower when machining glass, 33
% lower for tool steel, and about 35 % lower for sintered carbide.
• Water is commonly used as the abrasive carrying liquid for the abrasive slurry while
benzene, glycerol, and oils are alternatives.
• The increase of slurry viscosity reduces the removal rate.
• The improved flow of slurry results in an enhanced machining rate.
• In practice a volumetric concentration of about 30 to 35 percent of abrasives is
recommended.
• A change of concentration occurs during machining as a result of the abrasive dust
settling on the machine table.
• The actual concentration should, therefore, be checked at certain time intervals.
• The increase of abrasive concentration up to 40 % enhances MRR.
• More cutting edges become available in the machining zone, which raises the chipping
rate and consequently the overall removal rate.

3. Workpiece Impact Hardness

• MRR is affected by the ratio of tool hardness to workpiece hardness.

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 • In this regard, the higher the ratio, the lower will be MRR.
• For this reason soft and tough materials are recommended for USM tools.
4. Tool Shape
• Increase in tool area - decreases the machining rate; due to inadequate distribution of
abrasive slurry over the entire area.
• McGeough (1988) reported that, for the same machining area, a narrow rectangular
shape yields a higher machining rate than a square shape.
• Rise in static pressure - enhances MRR up to a limiting condition, beyond which no
further increase occurs.
• Reason - disturbance in the tool oscillation at higher forces where lateral vibrations are
expected.
• According to Kaczmarek (1976), at pressures lower than the optimum, the force
pressing the grains into the material is too small and the volume removed by a particular
grain diminishes.
• Measurements also showed a decrease in MRR with an increase in the hole depth.
• Reason - deeper the tool reaches, the more difficult and slower is the exchange of
abrasives from underneath the tool.

2.5 Surface Quality

 Surface finish - closely related to the machining rate in USM.

 Table shows the relationship between grit number and grit size.
TABLE 2

 Larger the grit size, faster the cutting rate but surface finish is poor.
 Surface finish of 0.38 to 0.25 μm can be expected using abrasives of grit number 240.

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2.6 APPLICATIONS
 Machining of cavities in electrically non-conductive ceramics
 Used to machine fragile components in which otherwise the scrap rate is high
 Used for multistep processing for fabricating silicon nitride (Si3N4) turbine
blades
 Large number of holes of small diameter could be machined. 930 holes with 0.32mm
has been reported ( Benedict, 1973) using hypodermic needles
 Used for machining hard, brittle metallic alloys, semiconductors, glass,
ceramics, carbides etc.
 Used for machining round, square, irregular shaped holes and surface
impressions.
 Used in machining of dies for wire drawing, punching and blanking
operations
 USM can perform machining operations like drilling, grinding and milling
operations on all materials which can be treated suitably with abrasives.
 USM has been used for piercing 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
 USM can be used to cut industrial diamonds
 USM is used for grinding Quartz, Glass, ceramics
 Cutting holes with curved or spiral centre lines and cutting threads in glass and
mineral or metallo-ceramics.

2.7 ADVANTAGES
 It can be used machine hard, brittle, fragile and non conductive material
 No heat is generated in work, therefore no significant changes in physical structure
of work material
 Non-metal (because of the poor electrical conductivity) that cannot be
machined by EDM and ECM can very well be machined by USM.
 It is burr less and distortion less processes.

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  It can be adopted in conjunction with other new technologies like
EDM,ECG,ECM.

2.8 DISADVANTAGES
 Low Metal removal rate.
 It is difficult to drill deep holes, as slurry movement is restricted.
 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.
 USM can be used only when the hardness of work is more than 45HRC

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 CHAPTER 3
CONCLUSION AND RECOMMENDATION

3.1 CONCLUSION AND RECOMMENDATION

It is clear from the derived Eqs. that the material Removal rate(MRR) depends on the amplitude
and frequency of vibration, static force, size of abrasive particle and property of tool and
workpiece. MRR in the hammering model is more than the throwing model. It is clear from the
graph that MRR increases as the amplitude of vibration increases upto an optimum
value,beyond this it starts decreasing. MRR also increases as the frequency of vibration and
pressure increases. As the grit size increases MRR also increase upto an optimum value after
that it stars deceasing

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REFERENCES

1. www.google.com
2. www.wikipedia.com
3. www.studymafia.org

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