Name - Adil Hossain

Reg No - RA1511002010247
Semester -6
Course - Multi Disciplinary Design
Faculty -Mr. S. Shakthivel

Paper Presentation

On

‘Ultrasonic Machining And

its advancements’
  Ultrasonic machining
Ultrasonic machining is a manufacturing process that removes material through
high frequency, low amplitude vibrations of a tool against the material surface in
the presence of fine abrasive particles. The fine abrasive grains are mixed with
water to form a slurry.

 Need for Ultrasonic machining

Hard and brittle materials which are often difficult to machine. Manufacturing
fragile materials such as glass and non-conductive metals and high-tolerance parts.

 Papers Presented on the Topic :-

Paper 1 : Machining Process Parameters of USM- A Review by Dipesh Popli,

Ravi Pratap Singh and Dr. Meenu Gupta

The paper emphasized on the fact that process parameters is crucial for achieving
optimum value of MRR and Surface finish in ultrasonic machining. Experimental
analysis was done by varying the parameters such as slurry concentration,
hardness, abrasive grit size, input rate etc. and different process parameter for
different type of material was studied. The following results were obtained.
 Brittle – Machining accuracy depends more on abrasive grit size.
 Glass – grit size was most vital parameter and slurry conc. was least
 Titanium - MRR is directly related to the energy input rate.
 Alumina based ceramic - MRR decreases with increase in alumina
content in the workpiece.

Paper 2 : A Comparative Study on Ultrasonic Machining of Hard and Brittle

Materials by P.L Guzzo, AH Shinohara and AA Rasian.

This paper investigates the machining of hard and brittle materials. The material
removal rate or the cutting rate (CR) was determined by measuring the time
expended to machine a given depth (p) in several stages of machining. The result
obtained was that the rate of material abruptly decreased with the machining depth
for workpiece materials in which hardness is at the same order of magnitude as that
of the hardness if abrasive grits.

For alumina, zirconia and quartz the cutting ratio decreased with the cutting depth
whereas in the case of LiF, glass, ferrite the cutting ratio seemed to be independent
of the depth. The main difference between these 2 groups is its hardness. Above a
certain valued of hardness, the abrasive particles lose its cutting power.

Paper 3: Recent Advancements in Usm Machining – A review paper by

Pardeep Kumar, Sunil Kumar and Manpreet Singh.

In this paper different mechanism for different materials were studied like brittle,
ceramics, titanium alloys etc. and different mechanism involved in the machining
of different materials. The following result were obtained: -
 Hard and brittle (Glass) – Direct hammering of abrasives with the
vibrating tool.
 Ceramic Composites – Increase in grain size of abrasive enhances Surface
roughness.
 Ceramic Coated Nickel Alloys – By combining ultrasonic during electric
discharge machining process.
 Silicon Carbide – Using rotary ultrasonic machining.

Paper 4: EXPERIMENTAL STUDY OF MICRO ULTRASONIC

MACHINING PROCESS by Sreenidhi Cherku, Murali M Sundaram and KP
Rajurkar.

In this paper, the metal removing rate and surface roughness against various
particle size and also the variation when machining in oil-based slurry and water
bases slurry was studied. The conclusion was evident that machining with water-
based slurry is suitable only for finer particle sizes with higher concentration or
medium particle sizes with medium concentration or coarse particle sizes with
lower particles. Whereas machining with oil based slurry is always suitable for all
particle sizes with lower concentration.
Also the study reveals that machining with oil based slurry gives good surface
finish compared to the water based slurry. Good surface finish is given by
machining with finer particle whereas machining with coarser grains gives poor
surface finish.

Paper 5: Recent advances in ultrasonic assisted turning: A step towards

sustainability by Varun Sharma and Pulak M. Pandey

In this paper ultrasonic assisted turning is studied for machining difficult to cut
materials like alloys of nickel, titanium and composite materials. The paper studies
the advantages of UAT in terms of cutting forces and stress levels compared to
conventional UAT. The following conclusions were achieved.
(1) A decrease in the average cutting forces is observed in
(2) A proper selection of the cutting and vibration
(3) For machining materials with poor thermal conductivity
(4) The compressive residual enhance the fatigue life of the component.