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Module-3: Advanced Material Removal Processes: Lecture No-8 Ultrasonic Machine and Its Process Parameters
Module-3: Advanced Material Removal Processes: Lecture No-8 Ultrasonic Machine and Its Process Parameters
Lecture No-8
The purpose of the OC generator is to produce high frequency oscillating currents. This
generator transmits electrical power to the transducer which creates energy impulses in
the ultrasonic range i.e. 18-20 KHz and converts them into mechanical vibrations. The
primary function of the transducer is to convert electrical impulses into vertical and two-
dimensional strokes.
This is the ‘heart’ of the whole equipment and consists of two parts,
(a) The transducer, which converts the high frequency output of the generator
into linear vibrations and
(b) The trunk, which mechanically amplifies the linear vibrations.
Ultrasonic transducer
The ultrasonic vibrations are produced by a transducer that is driven by the signal
generator which gets further powered by an amplifier. The USM transducer works on the
following principle:
Piezo-electric effect
Magneto-strictive effect
Electro-strictive effect
The function of ultrasonic transducer is to converts high frequency electrical impulses
from the oscillator into mechanical vibrations. The periodicity of these vibrations
periodically shortens and lengthens. For low power applications piezo-electric
transducers are used, whereas for high power applications magneto-strictive transducers
are commonly used.
The trunk
It is a critical link in the ultrasonic machining system. It is known by several names such
as shank, horn, concentrator and amplifier. The trunk amplifies and focuses vibrations of
the transducer to the required intensity necessary enough for driving the tool. The
increase in amplitude of vibrations at the tool end is obtained by reducing the cross
section of the trunk.
The Tool
The tool is designed to provide the maximum amplitude of vibration at the free end. The
selection of tool material is very important as the tool tip is subjected to vibration and it
must not fail due to wear. The commonly used tool materials are brass, high speed steel,
mild-steel, silver, stainless steel, tungsten carbide and monel. The tool is attached to the
trunk (horn) by silver brazing or by hard soldering. At times it is fastened (screwed) with
the trunk.
The recommended slurry to be used in this process is a mixture of abrasive particles and
liquid (water or kerosene). The slurry is pumped across the tool face. Slurry pump is a
part of the machine-system. The properties required from the transport medium of
abrasives include low viscosity, good wetting and high thermal conductivity. Water is a
recommended medium for abrasive transportation which generally meets most of the
process requirement.
Process Parameters in USM
Machine Parameters
These are those parameters which can be set on the machine. They include frequency and
amplitude of the ultrasonic vibrations, the static load, work piece rotation and tool-head
rotation.
The type and size of the abrasives particles, its hardness, type of the fluid used as a
carrier to form the abrasive slurry and the concentration of abrasive particles in the slurry.
The hardness, fracture characteristics, strength, work hardening tendency and fatigue
properties of the work material also affect the process performance.
The shape of the tool (solid or hollow), mechanical properties of the material used in
tool-making are some of the other parameters that may affect the USM process
performance.
Rotary
R Ultra
asonic Mach
hining (RUM
M)