Ultrasonic machining (USM)

Non-traditional machining

Ultrasonic machining
Non traditional means of uniform stock

removal
Is also known as ultrasonic collision
grinding or impact grinding
Differs from most other machining
operations since very little amount of
heat is produced
Has been around since the 50s. Primarily
used as surface finishing process for parts
made by electro-discharge machining

Ultrasonic machining
Can cut any material. Most effective on

very hard and brittle materials, where it

offers better surface finish, a lower
degree of surface degradation and
greater complexity of geometry
Some examples of such materials are
glass, quartz,sapphire,ferrite,aluminium
oxide,silicon,silicon carbide,silicon
nitride,ruby, diamond,fibre
opticsandceramics

Working principle
Ultrasonic machining is the elimination

of material by the abrading action of

micro stones-loaded liquid slurry
available between the work piece and a
tool vibrating at a 90 degree angle to
the work surface at a frequency more
than audible range (ultrasound).
The cutting tool oscillates at the
frequency range of 20kHz to 40kHz
The vibration amplitude of the
workpiece ranges from 15 20 microns

Working principle
Abrasive grains are actuated by the high speed

reciprocate motions across the small gap, in

between the tool and the work piece
There is no contact between the tool and the
workpiece. As a result, the grinding pressure is
rarely more than 2 pounds, which is perfect for
machining hard and brittle materials
The impact of abrasive particles is the energy
source which is mainly responsible in removal of
the material, through the form of small wear
particles which are carried away by the abrasive
slurry

Abrasive slurry
Provides constant source of abrasive particles
Carries away machining debris and fractured

particles
Circulated by a refrigerated pump system
Removes heat from the cutting process,
preventing boiling between the tool and
workpiece
Cutting action comes from accelerated
particles being repeatedly forced against the
workpiece surface

Abrasive slurry
The abrasive grit in the slurry medium is

typically of low cost and easily available.

Examples:
Aluminium oxide or silicon carbide is
used for glass
Boron carbide is used for die steel and
gems
Boron silicarbide
Diamond

Abrasive slurry
Typical grit size for the abrasive slurry

range from 100 to 800

Selection of abrasive particles depends on:
Type of material being machined
Hardness of material
Desired removal rate of material
Surface finish needed
Larger grit rougher cut
Smaller grit finer finished surface

Abrasive slurry
Water is typically used for ultrasonic

machining
Other fluid mediums are:
Benzene
Glycerol
Oils
Concentration of abrasive grains or grit in
water slurry ranges from 20% - 60% by
volume
Best average results are achieved around
30% concentration

Material removal rate (MRR)

MRR = 5.9 f (s/H) 0.5R 0.5y
Where
f = frequency of oscillations, Hz
H = surface fracture strength, BHN
s = static stress in tool, kg/mm^2
R = mean radius of grit, mm
y = amplitude of vibration, mm

Material removal rate

Some examples of different rate per

material:
Work material

Relative MRR

Glass

100.0

Brass

6.6

Tungsten

4.8

Titanium

4.0

Steel

3.9

Chrome steel

1.4

Ultrasonic machine parts

Ultrasonic machining consists of :
High power sine wave generator
Magnetostriction transducer
Tool holder
Tool

Magnetostriction transducer
Generates vibration
Works as an ultrasonic generator

converting electrical energy into

mechanical energy

Tool
The tool is made of an easily shaped,

softer material than the workpiece

Commonly used tool materials are nickel,
mild steel, carbide, tool steel or brass
The tool suffers very little deformation
during the process
Tool material is subject to wear, therefore
it is compulsory that proper care is given
to the selection of work-to-tool
combinations

Tool
Tool wear varies depending on the tool

material
Wear ratios are in the range of 1:1 to 100:1
(material removed vs. tool wear)
Ductile tool materials allow tool surface
hardening in some processes, thus increasing
wear ratios
At the same time it provides ease of
manufacture of tools by traditional processes
and thus create cost reduction in the creation
of tools making the entire process more
affordable

Advantages
Workpiece is free from burns and distortions
Free from stress and damages
The process is non-thermal, non-chemical, and

non-electrical, leaving the chemical and

physical properties of the workpiece
unchanged
Multiple features can be machined on the
workpiece simultaneously, and the process is
scalable
Good surface finish and structural integrity
Suitable for machining brittle materials

Disadvantages
Very poor material removal rate
Unable to make deep holes
Relatively high tool wear

Applications
Machining auto-engine components
Machining hard and brittle alloys,

semiconductors, glass, fiber material,

ceramics, carbides, etc
Drilling very fine holes in helicopter
power transmission shafts and gears

References
http://www.mechscience.com/4270-ultras

onic-machining-process-usm-concept-ofultrasonic-machining-process-usm/
http://www.eng.morgan.edu/~mahmud/IE
GR563/ultra.html