PRESENTATION FOR CA:- 1

Name : Souvik chakraborty

Roll No : 25500720008
Reg no-202550100720004
Subject : Advance machining Technology
Subject code : PC- ME -701
Topic : Ultrasonic Machining

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ULTRASONIC MACHINING

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 INTRODUCTION
 Manufacturing industries like aviation, nuclear, missile, tool
and die making now use newly developed hard and difficult-
to-machine materials demanding high precision and surface
finish.
 Difficulty in simultaneously achieving high degree of
precision and surface finish in the traditional methods of
machining has led to the development of some new machining
techniques.
 Material removal processes can be divided into two groups:
a. Conventional Machining Processes
b. Unconventional Machining processes

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CLASSIFICATION OF NON-CONVENTIONAL
MACHINING PROCESSES:

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 NEED FOR UNCONVENTIONAL MACHINING
PROCESS:
The main reason for using unconventional machining process are :
 To machine high strength alloys eg., Inconel, Titanium alloys,
etc.
 To produce complex surfaces.
 To achieve high accuracies and surface finish.
 Machining of composites.
 Deep hole with small hole diameter.
 Difficult to machine material.

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 ULTRASONIC MACHINING PROCESS:

 Ultrasonic machining is a non-traditional machining process,

grouped under the mechanical group NTM processes.
 USM is mechanical material removal process used to erode
holes or cavities on hard or brittle work piece by using shaped
tools, high frequency mechanical motion and an abrasive
slurry.

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 PRINCIPLE
 The time spent on ultrasonic machine entirely depends on the
frequency of the vibrating tool, size of grains of the abrasive
slurry, the rigidity and the viscosity as well.
 The shaped tool under the actions of mechanical vibration
causes the abrasive particles dipped in slurry to be hammered
on the stationary workpiece. This causes micro-indentation
fracture on the material.

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 WORKING

Schematic representation of Ultrasonic machining process

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Continue…

Schematic representation of material removal mechanism

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 EQUIPMENT
Ultrasonic Machining consists of:
 Power supply
 Transducer
a. Piezoelectric Transducer:
b. Magneto-strictive Transducer
 Tool Holder Amplifying tool holders, copper washers

 Tool
 Horn
 Abrasive slurry
 Work piece Different Horns used in USM

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 PROCESS PARAMETERS
 Amplitude of vibration (15 to 50 µm)
 Frequency of vibration (19 to 25 kHz)
 Feed force (F) related to tool dimensions
 Abrasive size and Abrasive material: Al203, SiC, B4C,
Diamond
 Slurry
 Contact area of the tool
 Volume concentration of abrasive in water slurry
 Work material

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 PROCESS CAPABILITIES
 Can Machine work piece harder than 40 HRC to 60 HRC like
carbides, ceramics, glass that cannot be machined by
conventional methods.
 Tolerance range 7 micron to 25 microns.
 Holes up to 76 micron have been drilled.
 Hole depth of 152mm deep is achieved by special flushing
techniques.
 Linear material removal rate: 0.025 to 25mm/min.
 Surface finish: 0.25 micron to 0.75 micron.

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 ADVANTAGES
 USM effectively machines precise features in hard, brittle
materials such as glass, engineered ceramics, quartz, etc.
 Produces fine finished and structured results.
 Unlike conventional machining methods, ultrasonic machining
produces no heat affected zone.
 Ultrasonic machining does not thermally damage the
workpiece or appear to introduce significant levels of residual
stress, which is important for the survival of brittle materials in
service.
 Can drill circular or non circular holes on hard materials.

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 DISADVANTAGES
 High tooling cost.
 Low material removal rate.
 High power consumption.
 The initial equipment cost is higher than conventional machine
tools.
 It is difficult to machine softer materials.
 It is difficult to drill deep holes, as slurry movement is
restricted.

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 APPLICATIONS
 Used for machining hard, brittle materials like glass, ceramics,
carbides, diamond, etc.
 Used in machining of dies for wire drawing, punching and
blanking operations.
 USM enables a dentist to drill a hole of any shape on teeth
without any pain.
 USM can be used to cut industrial diamonds.
 USM is used for grinding Quartz, Glass, ceramics.
 Coining and engraving applications.

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 CONCLUSION
 Ultrasonic machining (USM) is of particular interest for the
machining of conductive, non-conductive, brittle materials
such as engineering ceramics.
 USM process is purely depends on the work material
properties mainly hardness and fracture toughness, tool
properties, abrasive properties and process settings.
 The machining of materials such as Glass, super alloys,
ceramics, Tungsten carbide etc. to their final dimension by
conventional methods is extremely tough and generally not
possible. To overcome such kind of problems USM can be
utilized.

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THANK YOU