Materials Today: Proceedings xxx (xxxx) xxx

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Materials Today: Proceedings

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Response analysis of ultrasonic machining process under different

materials – Review
S. Sabareesan a,⇑, D. Vasudevan a, S. Sridhar a, R. Kannan a, V. Sankar b
a
Department of Mechanical Engineering, PSNA College of Engineering and Technology, Dindigul 624 622, Tamil Nadu, India
b
Department of Aeronautical Engineering, Nehru Institute of Engineering and Technology, Coimbatore 641105, Tamil Nadu, India

a r t i c l e i n f o a b s t r a c t

Article history: The different unconventional machining processes are used in modern development of material and
Received 5 October 2020 manufacturing industries. Ultrasonic Machining (USM) is changing the manufacturing industries with
Received in revised form 19 October 2020 its exceptional performance. Ultrasonic machining is an abrasive process which can be used for machin-
Accepted 22 October 2020
ing any material with the help of its vibrating tool and abrasive slurry. In this paper describes the material
Available online xxxx
removal mechanism, machining factors, machining with different materials and its process optimization
of USM through collection of different literature reviews. The advancement of the USM process and its
Keywords:
future scope has also been presented.
Ultrasonic machining process
Vibrating tool
Ó 2020 Elsevier Ltd. All rights reserved.
Abrasive slurry Selection and peer-review under responsibility of the scientific committee of the International Confer-
Material removal ence on Advances in Materials Research – 2019.
Machining factors

1. Introduction Rotary Ultrasonic Texturing (RUT) technology was introduced for

Ultrasonic machining was the best suitable process for machin-
ing hard materials such as ceramic matrix composites, quartz, fer-
rite, diamonds, sapphire and different carbides. The better process
results were obtained from this process such as super finish with
excellent accuracy. Due to vibratory motion of the tool, the differ-
ent shape of the profiles has been produced. It was used in process
of drilling, grinding, engraving, slicing and piercing. The semi-
precious stones can be easily machined. It was suitable for both
conducting and non-conducting materials. USM working principle,
material removal mechanism and its process factors have been
studied [1]. The surface roughness and accuracy of the machining
components were investigated in different materials such as glass,
porcelain, ferrite and alumina through different tool materials [2].
The ultrasonic vibrations were controlled and its machining accu-
racy has been improved [3]. The better machining quality of the
materials was attained though USM process [4]. The frictional
behavior of the tool–chip interface was studied in USM [5]. The dif-
ferent forces have been analyzed during ultrasonic turning process
[6]. The advanced computer numerical control RUAM 5-axis
machining centers were executed in modern USM process [7].
⇑ Corresponding author.
E-mail address: sabaree1987@gmail.com (S. Sabareesan).
micro and nano machining process [8,9].
The present review paper discussed about the ultrasonic
machining process, machining with different materials, process
parameters and its different optimization techniques (Fig. 1).
2. Ultrasonic machining process
The electromechanical transducer was produced the vibrations
and its transmitted to the tool. An abrasive gun was provided abra-
sive slurry, which was a combination of different abrasive grains
and the water with correct proportions. It was supplied in between
tool and work piece under a definite pressure. The microscopic
grains were removed from the work piece by abrasion. The mate-
rial removal was started through the combination of abrasive
slurry and mechanical vibrations. Aluminium oxide and different
carbide particles were used as the abrasives. Tool was fabricated
by copper, brass and stainless steel. The different input factors such
as power rating, slurry concentration and grit size have been con-
sidered for machining of duplex brass and its experimental results
were shown in Table 1. The power rating was the most powerful
factor which affects the MRR and SR followed by grit size [33].
The working mechanism and its development of rotary ultrasonic
machining have been investigated. It consists of five axis machin-
ing centres and it was operated by computer numerical control
[7]. The developed model was used to predict the material removal

https://doi.org/10.1016/j.matpr.2020.10.695
2214-7853/Ó 2020 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Conference on Advances in Materials Research – 2019.

Please cite this article as: S. Sabareesan, D. Vasudevan, S. Sridhar et al., Response analysis of ultrasonic machining process under different materials –
Review, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.10.695
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Materials Today: Proceedings, Corrected proof. doi:10.1016/j.matpr.2020.10.695

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Materials Today: Proceedings, Corrected proof. doi:10.1016/j.matpr.2020.10.695