ASSIGNMENT#3

GROUP #2
MANUFACTURING PROCESS
ULTRASONIC MACHINING
Group Member:
Aris Maknojia (me181037)
Hussain Hatim (me181047)
Haseeb Durrani (me181048)
Class:BE-ME-5B
CONTENT
 Introduction
 Difference between conventional and non-conventional Machining
 Ultrasonic Machining
 Need for Ultrasonic Machining
 Schematic diagram of Ultrasonic Machining
 Main Parts of Ultrasonic Machining
 Sub-parts of Ultrasonic Machining
 Working Principle of Ultrasonic Machining
 Process Parameters
 Applications Of Ultrasonic Machining
 Advantages of Ultrasonic Machining
 Disadvantages of Ultrasonic Machining
INTRODUCTION
 Material removal is a shaping process in which undesired excess material
is removed from the starting work piece so the remaining part becomes
closer to the desired shape.
 In other words we can define material removal process as the
manufacturing process in which we obtain a final product by removing
excess material from the work piece.
 The best example of a machining process is generating a cylindrical
surface from metal stock with the help of the lathe.
 Material removal process can be divided into two groups:
1. Conventional Machining Process
2. Unconventional Machining Process
DIFFERENCE B/W CONVENTIONAL AND
NONCONVENTIONAL MACHINING
Conventional Machining Non-conventional Machining
Direct contact of tool and work piece. Doesn’t require direct contact of tool and work piece.

Cutting tool is always harder than Tool may not be harder and it may not be physical
work piece. presence.

Tool life is less due to high wear. Tool life is more.

Conventional machining process has lower accuracy non-conventional machining has higher accuracy
and surface finish and surface finish.

Examples: turning, boring, milling, shaping etc. Examples: Ultrasonic machining, Abrasive jet
machining etc.
 ULTRASONIC MACHINING
 Ultrasonic machining is a subtractive manufacturing process or we
can say mechanical removal process that removes material from
the surface of a part through high frequency, low amplitude
vibrations of a tool against the material surface in the presence of
fine abrasive particles.
 It is a non-conventional machining process in which harder
material is machined. It is particularly suited for very hard (brittle
Material) such as graphite, glass, carbide and ceramics.
 It is used to erode material in the form of fine holes and cavities in
hard (brittle) work piece.
NEED FOR ULTRASONIC MACHINING
Ultrasonic machining are mainly use:
To achieve high accuracy and surface finish of high strength
material.
To produce complex shapes.
For machining of composites.
For producing deep hole with small hole diameter.
For high rate material removing.
For engraving.
SCHEMATIC DIAGRAM OF ULTRASONIC
MACHINING
 Main Parts of Ultrasonic Machining

The ultrasonic machining machine consists 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 workpiece by abrasion where it
contacts it.
SUB-PARTS OF ULTRASONIC MACHINING
1) Power Supply
2) Piezoelectric Transducer
3) Work Piece
4) Abrasive Slurry
5) Velocity Transformer
6) Tool
7) Abrasive Gun
 Power Supply: This is used to power the machining process.
 Piezoelectric Transducer: In general transducer converts the electric
signal to mechanical signal. Piezoelectric transducer is used to generate
mechanical vibration in ultrasonic machining.

 Work Piece: An object (usually hard or brittle) being worked on with the
tool or machine.

 Abrasive Slurry: Abrasive Slurry is delivered to interface between the

work piece and the tool. As shown in the diagram below:
-A water based slurry mostly of abrasive particle
used as an abrasive slurry in this machining process.
-Aluminum oxide , Silicon Carbide, Boron Carbide are
used as an abrasive particle in this slurry.
 Velocity Transformer: It is used to hold the tool firmly.
 Tool: The tool should be design in such a way that when the operation is
performed it does not go under brittle fracture. Hence tool should be made up of
tough, strong and ductile material like steel, stainless steel or high stainless
steel ,mild steel, copper, brass etc. The tool in Ultrasonic machining is made to
vibrate with high frequency in the midst of the flowing slurry.
- The shape of tool correspond to the shape to be produced in the work piece.
- Tools are usually 25mm long.
- Mass of tool should be minimum possible so that it does not absorb the ultrasonic
energy.
- Sometimes finishing or polishing operation on tool are required because their
surface finish will be reproduced in work piece.

 Abrasive Gun: An abrasive gun is used to supply an abrasive slurry which is a

mixture of abrasive grain and water in between tool-work piece interface under a
definite pressure.
WORKING PRINCIPLE OF ULTRASONIC MACHINING:
• When the AC power is supplied with high frequency, the transducer
starts vibrating longitudinally, which is then transmitted to the
penetrating shaped tool which oscillates at high frequency, typically
20-40KHz, in abrasive slurry. The tool is gradually fed with a
uniform force and allowing the abrasive slurry to flow through
between tool, workpiece interface. The high speed reciprocations
of the tool and the flow of abrasive slurry results in the removal of
thousands of microscopic grains from work material by abrasion.
• The machining time of the ultrasonic machining entirely depends
on the frequency of the vibrating tool, size of grain and the
viscosity of the abrasive slurry.
PROCESS PARAMETERS:

1. Frequency of vibration. (19-25KHz)

2. Amplitude of vibration. (15-50um)
3. Feed pressure. (P)
4. Feed force. (F)
5. Abrasive size. (15-150um)
6. Volume concentration of abrasive in slurry.
7. Contact area of tool.
APPLICATIONS OF ULTRASONIC MACHINING
 Used for machining round, square, irregular shaped holes and
surface impression.
 It is used for coining and engraving application.
 It can be used to cut industrial diamonds.
 Used in machining of dies for wires drawing, punching and
blanking operation.
 It enables a dentist to drill a hole of any shape on teeth.
 It is used in slicing and broaching hard materials .
ADVANTAGES OF ULTRASONIC MACHINING
 The machining process is simple and economical and requires less
time.
 This process is used for drilling both circular and non-circular holes
in very hard materials like carbide, ceramics etc.
 Unlike conventional machining methods, ultrasonic machining
produces no heat affected zone.
 Produce fine finished and structured results.
 It is not affected by the electrical or chemical characteristics of the
work piece.
DISADVANTAGES OF ULTRASONIC MACHINING
 It requires high power consumption and cost of tool is high, hence
cost of machining is high.
 Tool wear is high hence shorter tool life.
 Low removal material rate(3-15mm^3/min).
 It is difficult to machine softer materials.
 Sharp corners can not be produced.
 The process is limited to the machined surface of a small size .