ULTRASONIC

MACHINING
ARAVIND SUDHEESAN
ROLL NO- 01

INTRODUCTION
USM is the removal of hard and brittle materials using an axially oscillating

tool at ultrasonic frequencies [1830 kHz].

Abrasive slurry of B4C or SiC is continuously fed into the machining zone

between the tool and the workpiece.

The abrasive particles are hammered into the workpiece surface and cause

chipping of fine particles.

The oscillating tool, at amplitudes ranging from 10 to 40 m, imposes a

static pressure on the abrasive grains and the material is removed to form
the required tool shape

WORKING MECHANISM

Fig. 1 - USM components

1. MAGNETOSTRICTOR
The magnetostrictor used in USM has a high-frequency winding wound

on a magnetostrictor core and a special polarizing winding around an

armature.

This effect is used to oscillate the USM tool, which is mounted at the

end of a magnetostrictor, at ultrasonic frequencies of 18 to 30 kHz.

It uses longitudinal vibrations

Made up of Nickel(has high strength and good insulating properties),

Iron-cobalt (permendur), Iron-aluminium (alfer)

Deformation is independent of the direction of magnetic field, the

frequency of vibration of the magnetostriction assembly is twice that of

the driving field

Ferromagnetic material undergo dimensional change in a magnetic

field. A domain is a very small area of 10 -8 where magnetic field are

parallel. In the presence of an external magnetic field all domains aligns
in a single direction to give a dimentional change- Domain Theory

Fig. 2 - Magnetostriction transducer

2. MECHANICAL AMPLIFIER
The elongation obtained at the resonance frequency f r using a

magnetostrictor is usually 0.001 to 0.1 m, which is too small for practical

machining applications.

Amplitude amplification can be achieved by one or more acoustic horns

In order to have the maximum amplitude of vibration the length of the

concentrator is made multiples of one-half the wavelength of sound in the

concentrator (horn) material.

Five acoustic horns are commonly used namely cylindrical, stepped,

exponential, hyperbolic cosine, and conical horns

Fig. 3 - Two-step amplification in USM

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 Types of amplifiers
Cylindrical
Has max dia D1 is 85mm
Shown in fig as part L1, L3, L5

Exponential
Max dia D1 is 85mm
Max D1/D2 ratio is 13
Amplitude gain D1/D2
Used when tool mounting dia is 3 - 12.5 mm
Shown in fig as part L2

Straight Tgaper
Max dia D1 is 85mm
Max D1/D2 ratio is 4
Amplitude gain D1/D2
Used when tool mounting dia is 12.5 25 mm
Shown in fig as part L4

 Plain
Max dia D1 is 85mm
Max D1/D2 ratio is 1
Amplitude gain 1
Used when tool mounting dia is >37.5 mm

Stepped
Max dia D1 is 85mm
Max D1/D2 ratio is 2
Amplitude gain (D1/D2)2
Used when tool mounting dia is 25 37.5 mm

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3. TOOLS.
Tool tips must have high wear resistance and fatigue strength.
For eg. For machining glass and tungsten carbide, copper and chromium

silver steel tools are recommended.

Silver and chromium nickel steel are used for machining sintered carbides.
Tool is fed toward, and held against, the workpiece by means of a static

pressure that has to overcome the cutting resistance at the interface of the
tool and workpiece.

Different tool feed mechanisms include

Counterweight techniques (fig a & b)
Compact spring-loaded system (fig c)
Pneumatic (fig d)

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4. ABRASIVE SLURRY.
Composed of 50 percent fine abrasive grains (100800 grit number) of

boron carbide, aluminum oxide, or silicon carbide in 50 percent water.

The slurry is continuously fed to the machining zone in order to ensure

efficient flushing of debris and keeps the machining area cool.

The abrasive slurry is circulated between the oscillating tool and

workpiece.

Due to static feed force and the ultrasonic vibration, the abrasive particles

are hammered into the workpiece surface causing mechanical chipping of

minute particles.

The slurry is pumped through a nozzle close to the tool-workpiece interface

at a rate of 25 liters per minute

The expected life ranges from 150 to 200 h of ultrasonic exposure

The performance of USM depends on the manner in which the slurry is fed

to the cutting zone

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Fig. 4 - Slurry injection methods.

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MARERIAL REMOVAL
Mechanical abrasion by localized direct hammering (due to brittle fracture) of

the abrasive grains stuck between the vibrating tool and adjacent work
surface (dominant process)

The microchipping by free impacts of particles that fly across the machining

gap and strike the workpiece at random locations.

The work surface erosion by cavitation in the slurry stream( <5%)

Fig. 5 - Material removal mechanisms in USM

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 Brittle fracture
Impact of abrasive particles
Due to work hardening
Work surface becomes more brittle as a result

Shear flow (free impact)

Impact of the microscopic grains impinging on work surface and material and

wearing is formed by shear action

Cavitation
When tool goes up fluid cannot enter the gap due to small interval 1/20,000 s.

Hence pressure there drops and cavitation bubbles are produced. When they
break pressure of about 1000bars are produced removing material

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 MRR depends, on
The frequency of tool vibration,
Static pressure,
The size of the machined area,
The abrasive and workpiece material.

Soft and elastic materials like mild steel are often plastically deformed first

and are later removed at a lower rate.

In case of hard and brittle materials such as glass, the machining rate is

high and the role played by free impact can also be noticed.

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FACTORS AFFECTING MRR

Tool Vibration
MRR increases with a rise in the tool vibration amplitude.
It results in increase in velocity of particles
Enhances the mechanical chipping action and consequently increases the MRR.

A greater vibration amplitude may lead to the occurrence of splashing

Reduction of the number of active abrasive grains and results in a decrease in

the MRR.

Abrasive Grains
When the grain size is large compared to the vibration amplitude, there is a

difficulty of abrasive renewal.

The increase of slurry viscosity reduces the removal rate.

The increase of abrasive concentration up to 40 % enhances MRR.
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 Workpiece Impact Hardness

MRR is affected by the ratio of tool hardness to workpiece hardness-

higher the ratio, the lower will be MRR

Soft and tough materials are recommended for USM tools.

Tool Shape
Increase in tool area decreases the machining rate
Force pressing the grains into the material is too small and the volume

removed by a particular grain diminishes.

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APPLICATIONS
Drilling and coring- tool bit is rotated against the workpiece in a similar

fashion to conventional drilling.

Commonly known as Rotary Ultrasonic Machining (RUM)

The process allows the uninterrupted drilling of small-diameter holes, while

conventional drilling necessitates a tool retraction, which increases the

machining time.

It ensures
High material removal rates,
Lower tool pressures for delicate parts
Improved deep hole drilling
No core seizing during core drilling.

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 Ultrasonic sinking and contour machining During USM sinking, the material removal is difficult when the machined

depth exceeds 5 to 7 mm. Hence material removal is impossible

Contouring USM employs a tool that is a negative replica in the workpiece.

Production of EDM electrodes Typical ultrasonic machining speeds, to produce graphite electrode, range

from 0.4 to 1.4 cm/min.

The surface roughness ranges from 0.2 to 1.5 m and accuracies of 10

m are typical.

Ultrasonic polishing It occurs by vibrating a brittle tool material such as graphite or glass into

the workpiece at an ultrasonic frequency and a relatively low vibration

amplitude.

The fine abrasive particles, in the slurry, abrade the workpiece surface,

typically removing 0.012 mm of material or less.

Surface finish can reach up to 0.3 m

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 Micro-ultrasonic machining Micro-ultrasonic machining is a method that utilizes workpiece vibration.

Vibrating the workpiece allows for freer tool system design because it does

not include the set of transducer, horn, and cone.

Complete system is much more simple and compact.

Using such a method micro holes of 5-m diameter on quartz, glass, and

silicon have been produced using tungsten carbide alloy micro tools.

It can machine 3D holes as in figure

Fig. 6 Micro Ultrasonic machining of 3D holes

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ADVANTAGES
Retain sharp edges due to low wear rate
Better tolerance & good finish can be obtained
High fatigue strength for the tool an abrasives
Conductive and non conductive materials can be machined

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DISADVANTAGES
Low metal cutting rates
Depth of cylindrical holes are limited to 2.5 times dia of tool
Tool wear increases the angle of hole while sharp corner often are rounder
Due to lateral vibrations when the centre of gravity of the tool is not in line

with the machine the accuracy of the machined surface is reduced

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