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USM Ultra Sonic Machinig
Ultrasonic machining is a non-traditional machining process that uses high-frequency vibrations delivered to an abrasive tool tip to accurately machine hard and brittle materials without inducing stresses. The tool vibrates at 20-100 kHz with an amplitude of 0.025 mm while submerged in an abrasive slurry, and material is removed through micro-chipping as the abrasive particles are driven between the tool and workpiece. Ultrasonic machining works well for materials like aluminum oxides, silicon, glass, and ceramics that are difficult to machine through traditional methods.
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Overview of ultrasonic machining (USM) and its application in mechanical engineering by Vaibhav Tailor.
USM is a non-conventional process using high-frequency vibrations in abrasive slurry to create accurate cavities.
Effective for hard and brittle materials like silicon carbide and glass; soft materials reduce efficiency.
Ultrasonic waves higher than 20,000 Hz are used; tool vibrates at low amplitude to form cavities.
Material removed by micro-chipping with abrasive particles, as force transmitted through water slurry.
Mechanical properties affect roughness and cutting speed; higher hardness-to-elasticity ratio increases roughness.
Key parameters include vibration amplitude (15-50 μm), frequency (19-25 kHz), and abrasive size (15-150 μm).
Used for machining hard materials like alloys, semiconductors and creating various hole shapes.
USM has low material removal rate (MRR), high tool wear, and limited hole depth.
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USM Ultra Sonic Machinig
- 1. Dr. S. &S.S. Ghandhy College of Engg. & Tech. Ultrasonic MachiningUltrasonic Machining Department of Mechanical Engg. By VAIBHAV TAILOR
- 2. Ultrasonic Machining(USM) • Ultrasonicmachining is a non-conversational machining process. • high-frequency vibrations delivered to a tool tip, embedded in an abrasive slurry, by a booster, create accurate cavities of virtually any shape. • Since this method is non-thermal, non-electrical, and non-chemical, it produces virtually stress- free shapes even in hard and brittle work-pieces.
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- 4. Ultrasonic Machining(USM) • UltrasonicMachining 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.
- 5. Ultrasonic Machining(USM) • 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. • The tool, typically vibrating at a low amplitude of 0.025 mm at a frequency of 20 to 100 kHz, is gradually fed into the work-piece to form a cavity corresponding to the tool shape.
- 6. Ultrasonic Machining(USM) • Thevibration transmits a high velocity force to fine abrasive grains between the tool and the surface of the work-piece. In the process material is removed by micro- chipping or erosion with the abrasive particles. • The grains are in a water slurry which also serves to remove debris from the cutting area. The high-frequency power supply for the magneto-strictive or piezoelectric transducer stack that drives the tool is typically rated between 0.1 and 40 kW.
- 7. Ultrasonic Machining(USM) • Themechanical properties and fracture behavior of the work-piece materials also play a large role in both roughness and cutting speed. For a given grit size of the abrasive, the resulting surface roughness depends on the ratio of the hardness (H) to the modulus of elasticity (E). As this ratio increases, the surface roughness increases.
- 8. Process Parameters forUSM • Amplitude of vibration – 15 – 50 μm • Frequency of vibration – 19 – 25 kHz • Feed force – related to tool dimensions • Feed pressure • Abrasive size – 15 μm – 150 μm • Abrasive material – Al2O3 - SiC - B4C - Boronsilicarbide - Diamond • Flow strength of work material • Flow strength of the tool material • Contact area of the tool – A • Volume concentration of abrasive in water slurry – C
- 9. Application of USM •Used for machining hard and brittle metallic alloys, semiconductors, glass, ceramics, carbides etc. • Used for machining round, square, irregular shaped holes and surface impressions. • Machining, wire drawing, punching or small blanking dies.
- 10. Limitation of USM •Low MRR . • Rather high tool wear . • Low depth of hole .