Introduction to

Ultrasonic
Machining Processes
Contents:
 Ultrasonic Machining (USM)
 Introduction, Equipment and Material Process
 Effect of Process Parameters
 Effect of Amplitude and Frequency
 Effect of Abrasive Grain Diameter
 Effect of Slurry
 Tool & Work Material
 Process Characteristics
 Material Removal Rate
 Tool wear, Accuracy, Surface Finish
 Applications
 Advantages
 Limitations
Mechanical Non-Traditional Machining

USM WJM

Abrasion Cuttin
g

Abrasives Jet

Slurr Flui
y d
Work Piece Work Piece
 Ultrasonic Machining (USM)
Brief History
 The roots of ultrasonic technology dates back to 1880 when Mr. Pierre Curie
discovered through the research on piezoelectric effect.

 He found that asymmetrical crystals such as Quartz & Rochelle Salt (Potassium
Sodium Titrate) generate an electric charge when mechanical pressure was applied.

 U.S. Navy used ultrasonic waves during World War - II to detect enemy submarines.

 Today's Ultrasonic applications are used for machining, scanning, medical imaging
(scanning) and testing for cracks in automobiles and airplane construction.
Ultrasonic Machining (USM)
Process Description
 The tool (made of a ductile and material), which is negative of the
tough
workpiece, is vibrated at low amplitude (0.013 to 0.08 mm) and high
frequency

(about 20 kHz) in an abrasive grit slurry in the small gap between the tool and
the

work piece surface.


 The tool isalso
The slurry gradually
carriesmoved down maintaining
away the debris from a constant
the gap of approximately
cutting area.
0.1 mm between the tool and workpiece surface.
 The impact of the hard abrasive grains fractures the hard and brittle work
surface, resulting in the removal of the work material in the form of small
wear particles.
 The tool material being tough and ductile wears out at a much slower rate.
USM Equipment

Min Components

1) Power Supply
2) Transducer
3) Tool holder
4) Tool
5) Abrasives & Slurry
Power Supply

• Sine-Wave Generator is used as the source of power supply:

a) It is an excellent tool for generating waves with speakers or wave drivers.

b) It allows both the frequency (1-800 Hz) and amplitude of the sine wave output to be
varied.

• Frequency and power of signal generated are controlled by

the operator.
• It converts low-frequency (50/60 Hz) power to high frequency(10-
15kHz) power
• Supply to the transducer for conversion into mechanical motion.
Transducers

 It is a device that converts variations in a physical quantity,

such as pressure or brightness, into an electrical signal, or vice versa.

 Two types of transducers are used in USM to convert the supplied

energy to mechanical motion.

 They are based on two different principles of operation

 Magnetostriction
 Piezoelectricity
Magnetostriction Material

• When the material is placed in a sufficiently

strong magnetic field, the magnetic moments of
the domains rotate into the direction of the
applied magnetic field and become parallel to it.
• During this process the material expands or contracts, until all the domains
have become parallel to one another.
• very common magnetostrictive composite

• (smart material) is the amorphous alloy (Fe81Si3.5B13.5C2) with its trade

name (Metglas 2605SC)
Piezoelectric Transducer

• Such as quartz or Lead, Zirconate, Titanate, generate

a small electric current when compressed, their
dimensions alter when being subjected to
electrostatic fields.

• The charge is directionally proportional to the applied

voltage.
• Conversely, when an electric current is applied, the
material increases minutely in size.
• When the current is removed, the material instantly
returns to its original shape.
Tool Holder / Acoustic Head:

• Its function is to increase the tool vibration

amplitude and to match the vibrator to the
acoustic load.
• The Materials (Monel, Titanium and Stainless
steel) possess good acoustic properties and are
highly resistant to fatigue cracking.

• The shape of the tool holder is cylindrical or conical, or a modified cone

which helps in magnifying the tool tip vibrations.
• In order to reduce the fatigue failures, it should be free from nicks, scratches,
tool marks and should have a polished smooth surface.
 Different Horns used in USM
Tool Holder / Acoustic Head:

Exponential
The acoustic head can be of different shapes:

1. Tapered or
Conical
2. Exponential
3. Stepped Tapered
 The acoustic head is the most complicated part of
the machine.
 It must provide a static force, as well as the
high frequency vibration.
Stepped
Tools
: • Tools should be of relatively ductile & tough materials. Low carbon
steels and stainless steels give good performance.

• Tools are usually 25 mm long; its size is equal to the hole size minus

twice the size of abrasives.

• The harder the tool material, faster is its wear rate.

• Mass of tool should be minimum possible so that it does not absorb

the ultrasonic energy.

• It is important to realize that finishing or polishing operations on the
tools are sometimes
necessary because their surface finish will be reproduced in the work-
piece.
• The geometry of the tool generally corresponds to the geometry of
the cut to be made.
• Because of the overcut, tools are slightly smaller than the desired hole
or cavity.
• Tool and tool holder are often attached by silver brazing process.
 Abrasives and
Slurry:
The abrasive slurry contains fine abrasive grains
ranging from 15 μm – 150 μm.
 common types of abrasive are
- Boron Carbide (B4C) good in general, but expensive
- Silicon Carbide (SiC) glass,
- Germanium, Ceramics
- Corundum (Al2O3)
- Diamond (used for rubies , etc)
- Boron Silicon-Carbide (10% more abrasive than B4C)

• It is used to microchip or erode the work piece surface and it is also used to carry
debris away from the cutting area.
• Liquids used are:
- Water most common
- Benzene
- Glycerol
- Oils
 Materials that can be Machined by USM

• Hard materials like stainless steel, glass, ceramics, carbide,

quatz and semi-conductors are machined by this process.

• It has been efficiently applied to machine glass,

ceramics,
precision minerals stones, tungsten,
• Brittle materials