Ultrasonic Machining (USM)
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Ultrasonic machining uses a vibrating tool at ultrasonic frequencies to machine hard, brittle materials with little heat generation. It works by using an abrasive slurry between the tool and workpiece. The process allows machining of non-conductive materials that cannot be cut via other methods. It produces burr-free surfaces but has low material removal rates and high tool wear. Applications include machining ceramics, semiconductors, glass, and other hard materials, as well as drilling small, deep holes without damaging surrounding structures.
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Ultrasonic Machining (USM)
- 1. Ultrasonic Machining Presented by- P. Deepak Kumar
- 3. Introduction Also Known as Ultrasonic Impact Grinding. Vibrating tool at ultrasonic frequency. Use of abrasive slurry. Very little heat generated.
- 5. Working
- 7. Advantages  It can be used machine hard, brittle, fragile and non conductive material.  No heat is generated in work, therefore no significant changes in physical structure of work material.
- 8.  Non-metal (because of the poor electrical conductivity) that cannot be machined by EDM and ECM can very well be machined by USM.  It is burr less and distortion less processes.  It can be adopted in conjunction with other new technologies like EDM,ECG,ECM.
- 9. Disadvantages  Low Metal removal rate.  It is difficult to drill deep holes, as slurry movement is restricted.
- 10. Tool wear rate is high due to abrasive particles. Tools made from brass, tungsten carbide, MS or tool steel will wear from the action of abrasive grit with a ratio that ranges from 1:1 to 200:1. USM can be used only when the hardness of work is more than 45 HRC.
- 11. Applications  Machining of cavities in electrically non- conductive ceramics  Used to machine fragile components in which otherwise the scrap rate is high  Used for multistep processing for fabricating silicon nitride (Si3N4) turbine blades
- 12.  Used for machining hard, brittle metallic alloys, semiconductors, glass, ceramics, carbides etc.  Used for machining round, square, irregular shaped holes and surface impressions.  Used in machining of dies for wire drawing, punching and blanking operations
- 13.  USM has been used for piercing of dies and for parting off and blanking operations.  USM enables a dentist to drill a hole of any shape on teeth without any pain.  Ferrites and steel parts , precision mineral stones can be machined using USM
- 14. USM can be used to cut industrial diamonds USM is used for grinding Quartz, Glass, ceramics Cutting holes with curved or spiral centre lines and cutting threads in glass and mineral or metallo-ceramics
- 15. USM can perform machining operations like drilling, grinding and milling operations on all materials which can be treated suitably with abrasives. Large number of holes of small diameter. 930 holes with 0.32mm has been reported (Benedict, 1973) using hypodermic needles.
- 16. Thank you
Editor's Notes
- #4: Ultrasonic machining, also known as ultrasonic impact grinding, is a machining operation in which a vibrating tool oscillating at ultrasonic frequencies is used to remove material from the workpiece, aided by an abrasive slurry that flows freely between the workpiece and the tool. It differs from most other machining operations because very little heat is produced. The tool never contacts the workpiece and as a result the grinding pressure is rarely more than 2 pounds,which makes this operation perfect for machining extremely hard and brittle materials, such as glass, sapphire, ruby, diamond, and ceramics.
- #6: In ultrasonic machining, tool of desired shape vibrates at ultrasonic frequency ( 19 to 25 kHz. ) with an amplitude of 15-50 Microns over work piece. Generally tool is pressed down with a feed force F. Between the tool and work, machining zone is flooded with hard abrasive particles generally in the form of water based slurry. As the tool vibrates over the work piece, abrasive particles acts as indenter and indent both work and tool material . Abrasive particles , as they indent , the work material would remove the material from both tool and work piece. In Ultrasonic machining material removal is due to crack initiation, propagation and brittle fracture of material. USM is used for machining hard and brittle materials, which are poor conductors of electricity and thus cannot be processed by Electrochemical machining ( ECM) or Electro discharge machining (EDM). The tool in USM is made to vibrate with high frequency on to the work surface in the midst of the flowing slurry. The main reason for using ultrasonic frequency is to provide better performance. Audible frequencies of required intensities would be heard as extremely loud sound and would cause fatigue and even permanent damage to the auditory apparatus.