Nama : Handri Tirta Lianda

Nim : 2009521003

1. There is a fact that ultrasonic machining had found in 1965. What is the different with
todays UM??

2. Please make a review for below papers?

Answer

1. Todays UM used a diamond coated milling, boring and grinding tool.The tool
oscillates at high frequency and is fed into the work piece by a constant force. An
abrasive slurry comprising water and small abrasive particles is supplied between the
tool tip and the work piece material removal occurs when the abrasive particles
suspended in the slurry between the tool and work piece, impact the work piece due to
the down stroke of the vibrating tool.

 Main Parts:
The ultrasonic machining machine consist of two main parts transducer and
sonotrode (also called as horn), connected to an Electronic control unit with cables.
1. Transducer: The transducer mainly consists of a cylinder which is made up of
piezoelectric ceramic. It converts electrical energy into mechanical vibration.
Transducer then vibrates sonotrode at low amplitude and high frequency.
2. Sonotrode: It is made of low carbon steel. One end of it is connected with the
transducer and other end contains tool. The sonotrode vibrates at low amplitude and
high frequency and removes material from the w/p.
3. Control Unit: The control unit consists of an electronic oscillator which
produces an alternating current at high frequency. The frequency produced is
usually in between 20 kHz to 40 kHz. (in ultrasonic range).
 2.

 Working of USM
 The electronic oscillator and amplifier also known as the generator.
  It converted low frequency electrical energy in the high frequency power.
  It is supplied to the transducer.
  Transducer operate by magnetic friction
   Transducer is connected to the tool
 
2. Review for below papers

History:

 The first useful description of technique of ultrasonic machining was given in the
1940’s (Balmuth 1945).

 in 1964, first ultra-sonic machining tool was mostly on the basis of drilling and
milling has been build up by Rosenberg.
 The German company first used a diamond coated milling, boring and grinding tool.

Types of USM:
 Chemical-Assisted USM: 
In this machining, a chemically reactive abrasive fluid is used for the machining
process.
 Rotary Ultrasonic vibration machining (RUM): 
In RUM, a vertically rotating tool is allowed to revolve about the axis of the
sonotrode. The surface of the tool is impregnated with diamonds that is used to
grind down the surface of the work-piece. Abrasive slurry is not used in this type of
machine for material removal.
Merits of USM:

»   Materials difficult to machine on conventional machine  can be machined with good
accuracy and surface finish.

»    USM is suitable to precise machining brittle material.

»     USM does not produce electric, thermal, chemical abnormal surface.

»     Less stress because of its non-thermal characteristics.(stress free component)

»     Can drill circular or non-circular holes in very hard materials.

Demerits of USM:

»     Equipment is more costly than that of conventional machining process.

»     High tooling cost.

»     USM has low material removal rate. (3-15mm/min)

»     Tool wears fast in USM.

»     Abrasive slurry need be replaced periodically.

Applications: 

It is mainly used for

(1) drilling

(2) Surface grinding

(3) Profiling

(4) coining

(5) piercing of dies

(6) Threading,

(7) slot cutting

(8)    Used for machining round, square, irregular shaped holes and surface impressions.

       Etc.