Ultrasonic machining or USM is a non-traditional machining process that is used to remove material from a workpiece. The process uses high frequency, low amplitude vibrations to remove material from the workpiece. In USM, the material removal occurs due to the mechanical vibrations that are produced by the tool.
What is Ultrasonic Machining?
Ultrasonic machining is a non-traditional machining process that is used to remove material from a workpiece. It is a mechanical process that uses high frequency, low amplitude vibrations to remove material from the workpiece. The process is used to machine hard and brittle materials such as ceramics, glass, and semiconductors.
How Does USM Work?
The working mechanism of USM involves the use of a tool that vibrates at high frequency and low amplitude. The tool is placed in contact with the workpiece and a slurry of abrasive particles and water is used to remove material from the workpiece. As the tool vibrates, the abrasive particles in the slurry act as a cutting tool and remove material from the workpiece.
Types of Ultrasonic Machining
There are two types of ultrasonic machining ??? rotary ultrasonic machining (RUM) and ultrasonic assisted grinding (UAG). In RUM, the tool rotates and vibrates at the same time, while in UAG, the tool vibrates and moves back and forth in a reciprocating motion.
Advantages of USM
USM has several advantages over traditional machining processes. It can be used to machine hard and brittle materials that cannot be machined using traditional processes. It also produces a fine surface finish and does not produce any heat-affected zone.
Disadvantages of USM
USM also has some disadvantages. It is a slow process and cannot be used to remove large amounts of material. The tool life is also limited, and the process is expensive to set up.
Applications of USM
USM is used in various industries such as aerospace, automotive, medical, and electronics. It is used to machine components such as turbine blades, fuel injectors, and electronic components.
Factors Affecting Material Removal in USM
Several factors affect the material removal in USM. These include the amplitude and frequency of the tool vibrations, the slurry concentration, the pressure of the slurry, and the type of abrasive particles used.
Amplitude and Frequency
The amplitude and frequency of the tool vibrations are the most important factors that affect the material removal in USM. The amplitude determines the depth of cut, while the frequency determines the rate of material removal.
Slurry Concentration
The slurry concentration is another important factor that affects the material removal in USM. The slurry should have a high concentration of abrasive particles to ensure efficient material removal.
Pressure of the Slurry
The pressure of the slurry also affects the material removal in USM. A higher pressure of the slurry results in a higher rate of material removal.
Type of Abrasive Particles
The type of abrasive particles used also affects the material removal in USM. The abrasive particles should be hard and durable to ensure efficient material removal.
Conclusion
USM is a non-traditional machining process that is used to remove material from a workpiece. The process uses high frequency, low amplitude vibrations to remove material from the workpiece. USM has several advantages over traditional machining processes, including the ability to machine hard and brittle materials and produce a fine surface finish. However, it also has some disadvantages, including limited tool life and slow material removal rate. Several factors affect the material removal in USM, including the amplitude and frequency of the tool vibrations, slurry concentration, pressure of the slurry, and type of abrasive particles used.
