Ultrasonic Machining

Working Principle
Electrical energy of high frequency is converted into mechanical
vibration through a transducer.
These mechanical vibrations are transmitted to the abrasive particles
in the slurry via an energy focusing device (horn/tool assembly or
concentrator).
These abrasive particles then hit the workpiece surface causing its
erosion. This constant erosion leads to crack initiation and then by
brittle fracture actual machining takes place.
Process
In ultrasonic machining, a tool of desired shape vibrates at an
ultrasonic frequency (19 ~ 25 kHz) with an amplitude of around 15
50 m over the workpiece.
Between the tool and workpiece, the machining zone is flooded with
hard abrasive particles generally in the form of a water based slurry.
As the tool vibrates over the workpiece, tool hits the abrasive
particles which indent the work material. The abrasive particles, as
they indent, start erosion of the work material.
And then due to crack initiation, propagation and brittle fracture of
the material, machining will take place.
Representation of USM
USM equipment
Contd,
1. Sine wave generator or Amplifier:- Converts low frequency (60 Hz)
power supply to high frequency (19 to 25 KHz).
2. Transducer:- It converts the high frequency electric energy to
vibrating mechanical energy. It is also water cooled as excess eddy
current generation may lead to high heat.
3. Tool Holder/Horn/Concentrator:- It accommodates the tool.
transmits and concentrates vibrations from transducer to the tool.
4. Slurry Delivery system:- To supply constant abrasive slurry at the
tool work interface at a high speed.
Advantages
Noiseless operation.
Extremely hard and brittle materials can be easily machined.
It can produce cavities that are approximately mirror image of the
tool, leading to higher accuracies.
As no heat generation takes place, so physical properties of the
material surface also remain unchanged.
Disadvantages
High initial cost.
Lower MRR
High tooling cost.
Size of the cavity that can be machined are limited.
Higher power consumption.
Effect of various parameters
Abrasive velocity v/s MRR
Amplitude v/s Peneteration rate
Frequency v/s Peneteration rate
Slurry concenteration v/s Peneteration rate
Effects of abrasive velocity on MRR
MRR is directly
proportional to the
particle velocity that is
amplitude/resonant
frequency bears a linear
relationship to
machining rate. Thus
frequency used for
machining process must
be resonant frequency
of acoustic system.