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36 Non Conventional Machining

36 Non Conventional Machining



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Published by: PRASAD326 on Feb 04, 2009
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Version 2 ME, IIT Kharagpur
36Ultrasonic Machining(USM)
Version 2 ME, IIT Kharagpur
Instructional Objectives
i. Describe the basic mechanism of material removal in USMii. Identify the process parameters of USMiii. Identify the machining characteristics of USMiv. Analyse the effect of process parameters on material removal rate(MRR)v. Develop mathematical model relating MRR with USM parametersvi. Draw variation in MRR with different process parametersvii. Identify major components of USM equipmentviii. State the working principle of USM equipmentix. Draw schematically the USM equipmentx. List three applications of USMxi. List three limitations of USM
1. Introduction
Ultrasonic machining is a non-traditional machining process. USM is groupedunder the mechanical group NTM processes. Fig. 9.2.1 briefly depicts theUSM process.Slurry of abrasiveand waterVibration frequency f ~ 19 - 25 kHzAmplitude, a ~ 10 – 50
mForce, FHornToolWork
Fig. 9.2.1
The USM process 
In ultrasonic machining, a tool of desired shape vibrates at an ultrasonicfrequency (19 ~ 25 kHz) with an amplitude of around 15 – 50
m over theworkpiece. Generally the tool is pressed downward with a feed force, F.Between the tool and workpiece, the machining zone is flooded with hardabrasive particles generally in the form of a water based slurry. As the toolvibrates over the workpiece, the abrasive particles act as the indenters andindent both the work material and the tool. The abrasive particles, as theyindent, the work material, would remove the same, particularly if the workmaterial is brittle, due to crack initiation, propagation and brittle fracture of theVersion 2 ME, IIT Kharagpur

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