What Is Ultrasonic Machining?

l tesfbook
Loading
System

Abrasive
,.- - Cone
Slurry ~ - Horn
,,- - -Tool
Workpiece
J mp

Ultrasonic !Machining

Fig 1: Ultrasonic Machining

Ultrasonic machining is a non-conventional machining

process that utilises abrasive particles to remove
material from the workpiece. In this method, the tool
does not directly impact the workpiece, but rather the
abrasive particles are introduced between them. These
rigid and hard abrasive particles enable impact erosion
on the workpiece material, resembling a mode of
percussion. The process involves using a ductile tool
material to prevent brittle fracture during the hammering
action, resulting in precise material removal and delicate
machining of intricate components .
Parts of Ultrasonic Machining
Ultrasonic Machining comprises several essential parts
that work harmoniously to achieve precise material
removal:

Power Supply:

The power supply, also known as a high-frequency

generator or electronic oscillator, converts a standard
electrical supply into a high-frequency electrical supply,
typically ranging from 20-40 kHz, with small vibration
amplitudes in the range of microns.

Velocity Transformer:

The velocity transformer, or horn, amplifies and focuses

the vibration of the ransduce- to an intensity suitable for
driving the tool during cutting operations. It is made of
hard, non-magnetic, and easily machinable materials like
K-Monel, metal bronze, or mild steel.

Tool:

The tool, made of a ductile material, undergoes

hammering or percussion using abrasive particles to
remove material from the workpiece. Tool wear and
fatigue resistance are crucial, as ultrasonic frequencies
increase the hammering rate to enhance material •
removal. m
Abrasive Slurry:
Abrasive Slurry:

A slurry of abrasive particles is applied between the tool

and workpiece to facilitate material removal. The
abrasives, such as boron carbide or silicon carbide, are
rigid and hard, ensuring efficient machining. Fresh
abrasives are continuously supplied through a water jet
to maintain optimal machining efficiency.

Electro-Mechanical Transducer:

The transducer converts electrical energy into

mechanical vibrations, transmitting high-frequency
signals with low amplitude to the tool. Two types of
transducers are used: piezoelectric transducers and
magnetostrictive transducers.

Abrasive Gun:

The abrasive gun delivers the abrasive slurry to the

machining site through a water medium, ensuring a
constant supply of fresh abrasives under controlled
pres~urP. The water jet also removes debris and broken
abrasives during machining.

Workpiece:

Ultrasonic Machining is ideal for machining brittle non-

conductive materials, such as engineering ceramics,
without introducing thermal damage or residual stress.
This process enables intricate 3D shapes to be m ~
with precision on the workpiece. ~
• The working principle of Ultrasonic Machining
involves maintaining a 0.25 mm gap between the
ductile tool and the workpiece, with a slurry of
abrasive particles in between. As the tool moves
downward, the embedded abrasives hammer the
workpiece, effectively removing material. The slurry
facilitates material flushing from the machining area,
ensuring clean results and allowing for the creation
of straight holes with a slightly tapered tool.
• In Ultrasonic Machining, varying certain parameters
affects the material removal rate (MRR). Increasing
the viscosity of the carrier fluid leads to a decrease in
MRR due to reduced flushing efficiency. Elevating the
frequency results in increased MRR as more impacts
occur per unit time. Similarly, raising the amplitude
boosts MRR by enhancing the momentum of the
abrasives. The amplitude of vibration can vary
between 5 to 75 µm, while the frequency ranges from
19 to 25 kHz.
• Moreover, MRR can be influenced by adjusting the
concentration and size of the abrasives. Higher
abrasive concentration leads to more impacts and
increases MRR until a point where collisions between
the abrasive particles cause momentum loss,
subsequently reducing MRR. Similarly, increasing the
size of the abrasive results in a larger impact area,
but exceeding a certain size diminishes the
momentum of the abrasives.
• In terms of material removal rate, it is essential~
note that Ultrasonic Machining (USM) ranks bJ~ ~
Electrochemical Machining (ECM) and Electrical
Applications of Ultrasonic Machining
Ultrasonic Machining finds versatile applications in
various industries owing to its unique capabilities:

• Machining of Non-Conductive Ceramics: Ultrasonic

Machining excels in machining non-conductive
ceramics, making it ideal for precision shaping and
intricate designs in ceramic components.
• Machining Fragile Materials: Materials with high
scrap rates, particularly fragile substances, can be
effectively machined using Ultrasonic Machining,
ensuring minimal material wastage and precise
outcomes.
• Dies for Wire Drawing, Punching, and Blanking: The
process is employed to fabricate dies used in wire
drawing, punching, and blanking operations,
achieving accuracy and consistency in die
production.
• Dentistry Applications: Ultrasonic Machining enables
dentists to drill holes of any shape in teeth without
causing pain, providing a precise and painless dental
treatment experience.
• Grinding of Quartz, Glass, and Ceramics: It is used for
the precise grinding of materials like Quartz, Glass,
and ceramics, ensuring high-quality surface finishes
and dimensional accuracy.
• Cutting Industrial Diamonds: Ultrasonic Machining is
utilised to cut industrial diamonds, achieving precise
and intricate cuts in these valuable and hard
materials.
(i)
Advantages of Ultrasonic Machining
Ultrasonic Machining offers several advantages that
make it a preferred choice for specific applications:

• Machining of Brittle, Non-Conductive, Hard, and

Fragile Materials: Ultrasonic Machining excels in
machining materi1als that are brittle, non-conductive,
and hard, as well as fragile substances, providing
precise shaping and material removal.
• Negligible Heat Generation: Due to the absence of
heat generation, Ultrasonic Machining causes
minimal physical changes in the workpiece, ensuring
the preservation of material properties and
dimensional stability.
• Suitable for Non-Metallic Materials: Materials with
poor electrical conductivity, which cannot be
machined effectively by EDM and ECM, can be readily
processed using Ultrasonic Machining.
• Burr-Free and Distortion-Free Process: Ultrasonic
Machining results in burr-less and distortion-free
machining, producing clean and precise finished
surfaces.
• Compatibility with Other Technologies: Ultrasonic
Machining can be combined with other advanced
technologies such as EDM, ECG, and ECM, providing
enhanced capabilities and versatility in material
removal processes.
• Noiseless Operation: The operation of Ultrasonic
Machining is noiseless, making it suitable for . .
applications where low noise levels are require~~
• User-Friendly Equipment: The equipment used in
• I I I • I I • I I I
I I I ■ • a • I • •
Disadvantages of Ultrasonic Machining
Ultra sonic Mach ining , despite its advantages, come s
with certa in limita tions :

• Low Mate rial Removal Rate: Ultra sonic Mach ining

exhib its a relatively low mate rial removal rate
comp ared to some conv entio nal mach ining meth ods,
maki ng it less suita ble for high- volum e mate rial
removal appli catio ns.
• High Energy Requirement: The proce ss dema nds a
comp arativ ely highe r energy input for cuttin g
operations, whic h can impa ct the overall effici ency
and operating costs .
• Diffic ulty in Mach ining Soft Materials: Soft mate rials
pose challenges in Ultra sonic Mach ining due to their
susc eptib ility to defo rmat ion and dama ge unde r the
inten se impa ct of abrasive parti cles.
• Limit ed Deep Hole Mach ining : Drilling deep holes can
be challenging in Ultra sonic Mach ining as the
move ment of slurr y becomes restricted, poten tially
hinde ring effec tive mate rial removal.
• High Tool Wear Rate: The presence of abrasive
parti cles in the slurr y leads to increased tool wear,
reducing tool life and requiring more frequ ent tool
replacements .
Abrasive jet machining is the process
of impinging the high-speed stream
of abrasive particles by high-pressure
gas or air on the work surface
through a nozzle and metal removal
occurs due to erosion caused by
high-speed abrasive particles.
Because of repeated impacts small
bits of material get loosened which is
carried away by jet and exposes the
fresh surface to the jet.
Abrasive Jet Machining
Parts Or Construction
Abrasive Jet machining Consists of
the following parts

• Gas Supply
• Filter
• Pressure Gauge
• Regulator
• Mixing chamber
• Nozzle

control
valve

photo by Skyfi Labs

 • Gas is supplied to the system
for the operation. Here we also
use compressed air instead of
other gas.

Filter

• Filter indicates the cleanness

of the fuel supply.
• Here the work is to clean the
fuel if there are any dust
particles present.

Pressure Gauge

• This device will check whether

the required amount of
pressure is there or not.
• Normally this device works to
V
 Regulator

• The regulator as the name

indicates it controls the flow.
• It controls the compressed air
flowing through the pipe.

Mixing Chamber

• Here we supply the abrasive

particles and there already the
amount of compressed air
comes from the pipe.
• Both will get a mix that's why
this is called a Mixing
chamber.

Nozzle

• This is made up of hard

V material. The diameter of the
Nozzle

• This is made up of hard

material. The diameter of the
nozzle is about 0.18 to 0.8
mm.

Working Principle Of
Abrasive Jet Machining

Prr.5-Surc- pugc

n,. 4 3 : ,\b~siYc: kt Mxllioiu;

 Working Principle Of
Abrasive Jet Machining

l Cor::iirct•~ bosc

·-
I
Ptr-"UIC' g;sugc

The figure shown is the above

Abrasive jet Machining. It consists of
a mixing chamber, gas filter, pressure
gauge, regulator, and nozzle. The
filtered gas at a pressure of 2 to 8
kgf/cm 2 is supplied to the mixing
chamber containing the abrasive
powder and vibrating at 50 Hz, where
it mixes with abrasive particles and
v !n enters into the connecting hose.
powder and vibrating at 50 Hz, where
it mixes with abrasive particles and
then enters into the connecting hose.

The abrasive and gas mixture comes

out from the nozzle at a high velocity
ranging from 150 to 300
meters/minute and impinges over
the work surface causing abrasion
action by repeated impacts and the
material is removed by erosion. The
abrasive power feed rate can be
controlled by the amplitude of
vibration of the mixing chamber. A
pressure regulator controls the gas
flow and pressure.
To control the size and shape of the
cut, either the workpiece or nozzle is
moved by cams, pantographs, or any
other suitable mechanism. The
carrier gas should be cheap and non-
toxic and easily available, It is
generally air or nitrogen. Abrasive
generally used are Aluminum oxide,
Silicon carbide, or glass powder.

The nozzle is generally made of

harder material such as ceramic or
tungsten carbide to reduce abrasion
wear. The material removal rate
depends on the diameter of the
nozzle, jet pressure, composition of
mixtures, Hardness of abrasive
particles and workpiece, Particle size,
the velocity of the jet, and distance
between work and nozzle.
1pplications Of Abrasive
et Machining
• Cutting slots and thin
sections.
• Contouring and drilling
operation.
• Producing shallow crevices
and deburring.
• Producing intricate hole
shapes in a hard and brittle
material.
• Cleaning and polishing the
plastic, nylon, and Teflon
component.
• Frosting of the interior surface
of glass tubes.
• Etching of marking of glass
cylinders.
• Machining super-alloys and
 Applications Of Abrasive
Jet Machining
• Cutting slots and thin
sections.
• Contouring and drilling
operation.
• Producing shallow crevices
and deburring.
• Producing intricate hole
shapes in a hard and brittle
material.
• Cleaning and polishing the
plastic, nylon, and Teflon
component.
• Frosting of the interior surface
of glass tubes.
• Etching of marking of glass
cylinders.
• Machining super-alloys and
refractory material.

A
 . - . . .

Abrasive Jet Machining

Advantages
• The surface finish can be
obtained smooth.
• The cost of equipment is low.
• Ability to cut fragile and heat-
sensitive material without
damage.
• Ability to cut intricate hole
shapes in hard and brittle
material.
• The main advantages are its
flexibility, and low heat
production.
Abrasive Jet Machining
Disadvantages
• The material removal rate is
low.
• Poor machining accuracy.
• High nozzle wear rate.
• The soft material cannot be
machined.
• Additional cleaning of the
work surface is required due
to the sticking of abrasive
grains in softer material.