Ultrasonic machining is of particular interest for the cutting of nonconductive, brittle workpiece materials such as engineering ceramics. Ultrasonic machining is a nontraditional machining process. These noncontact devices are available in models that can convert readings into 420 ma outputs to dcss, plcs, or other remote systems. Its principle is to make the toolworkpiece interaction a microscopically non monotonic process to facilitate chip separation and to reduce machining forces. Ultrasonic vibrationassisted uva machining is a process which makes use of a microscale high frequency vibration applied to a cutting tool to improve the material removal effectiveness. Laser beam machining introduction, material removal 198.
Jun 03, 2014 principle of ultrasonic machining 1 this is the standard mechanism used in most of the universal ultrasonic machines 632014 hareesha n g, dept of aero engg, dsce 11 12. This chapter presents usm and rotary ultrasonic machining rum, including definitions, machine elements, input variables and their effects, applications, and advantages and disadvantages. Virtually all materials which reflect sound can be detected, regardless of their colour. The application of ultrasonic vibrations to a workpiece or tool is a novel hybrid approach in microelectrical discharge machining. The tool travels vertically or orthogonal to the surface of the. A comparative study on ultrasonic machining of hard and. The second approach is based on the transfer of the ultrasonic vibrations directly on the cutting tool, respectively directly to a cutting process. An experimental study on ultrasonic machining of an. The machining characteristics that are being investigated are tool wear rate and the quality of the. An experimental study on ultrasonic machining of pure titanium using designed experiments in the present research work, the effect of several process parameters on the machining characteristics of pure titanium astm gradei has been reported. The tool travels vertically or orthogonal to the surface of the part at amplitudes of 0. The process is nonchemical, nonthermal and nonelectrical, leaving the physical and chemical properties of the work piece unchanged. Silfex ultrasonic machining, also known as ultrasonic impact grinding, combines ultrasonic vibrations with abrasive slurry to create cavities of any shape in hard, brittle materials silicon, silicon nitride, silicon carbide, glass, alumina, quartz, sapphire, graphite. Introduction, mechanism of material removal, the machining system, material removal rates, heataffected zone, applications.
Ultrasonic machining is of particular interest for the cutting of non conductive, brittle workpiece materials such as engineering ceramics. Ultrasonic machining is nontraditional machining process which is used to machine brittle and hard material. Principle of ultrasonic machining 1 this is the standard mechanism used in most of the universal ultrasonic machines 632014 hareesha n g, dept of aero engg, dsce 11 12. Sep 01, 2015 working principle of ultrasonic machining. Ultrasonic machining is a mechanical type nontraditional machining process. Ultrasonic enhancement of an electrochemical machining process. Working principle ultrasonic sensor series ultrasonic waves are waves with frequencies above the frequency of the sound waves of more than 20 khz. Advantages and disadvantages of ultrasonic machining. Ultrasonic machining is a non conventional machining process. Ultrasonic vibrationassisted uva machining is a process in which a highfrequency vibration with a microscale amplitude is applied to the motion of the cutting tool or the workpiece to generate. In micro usm workpiece which is placed on the workpiece table vibrates at ultrasonic frequency. Rotary ultrasonic machining rum is a nontraditional machining process that combines the material removal mechanisms of diamond grinding and ultrasonic machining.
The process is non chemical, non thermal and non electrical, leaving the physical and chemical properties of the work piece unchanged. As it has been mentioned that the ultrasonic sensor consists of an ultrasonic transmitter circuit called ultrasonic transmitter and receiver circuit called a receiver. Experimental study of micro ultrasonic machining process. Micro ultrasonic machining microusm is a process with a great capability to generate micro features in hard and brittle materials. Ultrasonic machining is a mechanical type non traditional machining process. Ultrasonic machining is a method of grinding that uses an abrasive liquid rather than direct tool contact. In ultrasonic machining, a liquid filled with abrasive material flows through over the work piece, and the work tool vibrates against the abrasives. Particularly suited for very hard andorbrittle materials such asgraphite, glass, carbide, and ceramics.
The ultrasonic machining center is also a fully capable conventional machining center. May 30, 20 working principle ultrasonic sensor series ultrasonic waves are waves with frequencies above the frequency of the sound waves of more than 20 khz. It is employed to machine hard and brittle materials both electrically conductive and. Ultrasonic machining is a non traditional process, in which abrasives contained in a slurry are driven against the work by a tool oscillating at low amplitude 25100 microns and high frequency 1530 khz. Hcsr04 ultrasonic sensor consists of a transmitter, a receiver and a control. This paper did a comprehensive analysis on ultrasonic machining mechanism in theory. Because ultrasonic machining is not broadly adopted by brazilian manufacturing industries, the first part of this paper was devoted to recall the principle of operation and the main features of this process. There are also a number of instances where ultrasonic machining has been combined with other specialized machining techniques, notably electrolytic erosion.
The machining operation is simple and requires less time. Paul,department of mechanical engineering, iit kharagpur. Ultrasonic machining elements of process, cutting tool system design, effect of parameters. Modeling of material removal rate in rotary ultrasonic. Hydrodynamic cavitation machining hcm, and ultrasonic cavitation machining ucm, they will be introduced, and the parameters associated with them will be presented. Particularly suited for very hard andorbrittle materials such asgraphite, glass, carbide, and. Despite some developments in microusm process, issues such as precision measurement and control of the machining force, which is crucial for stable machining conditions, need further investigations. Because ultrasonic machining is not broadly adopted by brazilian manufacturing industries, the first part of this paper was devoted to recall the principle of. This ultrasonic transducer is embedded, watertight, into the sensor housing, in. Unit i mechanical processes ultrasonic machining elements. Unlike other non traditional processes such as laser beam, and electrical discharge machining, etc. Ultrasonic machining usm is a nontraditional mechanical machining process and can be used in many applications.
The time spent on ultrasonic machine entirely depends on the frequency of the vibrating tool. In the present paper, an experimental study of the ultrasonic based depassivation process and its benefits related to an ecm proces are presented and discussed. Ultrasonic technology poised for advance into general. During ultrasonic material removal, however, the machine holds an abrasive tool instead. Basics of ecm process electrochemical machining ecm for conductive. Wire electrical discharge machining wedm is an advanced thermal machining process capable of accurately machining parts with complicated shapes, especially for the parts that are very difficult to be machined by traditional machining processes. Schematic of ultrasonic machine tool usm is primarily targeted for the machining of hard and brittle materials dielectric or. A new nontraditional machining method using cavitation. It also depends on the size of grains of the abrasive slurry, the rigidity and the viscosity as well. Patil s, joshi s, tewari a et al 2014 modelling and simulation of effect of ultrasonic vibrations on machining of ti6al4v. A wide range of wedm industrial applications are reported together with the development of the hybrid machining processes. The fundamental principles of ultrasonic machining, the material removal mechanisms involved and the effect of operating parameters on material removal rate, tool wear rate and workpiece accuracy.
Match listi machining process with listii associated medium and select the correct answer using the codes. The transducer for usm works on the following principle piezoelectric effect magnetostrictive effect. Ultrasonic machining,direct impact,abrasive grains,material removal rate. Ultrasonic machining usm is the removal of material by the abrading action of gritloaded liquid slurry circulating between the workpiece and a. The advantages of this method include effective flushing out of debris, higher machining efficiency and lesser shortcircuits during machining. Machining ultrasonic machining the industrial resource. This process is used for drilling both circular and noncircular holes in very hard materials like carbide, ceramics, etc.
Ultrasonic machining from the technology data exchange linked to trusted tde listed vendors. Ultrasonic sensors emit short, highfrequency sound pulses at regular intervals. It generates high frequency sound and calculate the time interval between the sending of signal and the receiving of echo. Hadi is with the manufacturing department, university of tabriz, tabriz 51664, iran corresponding author to provide phone. Peia, clyde treadwellb 6 adepartment of industrial and manufacturing systems engineering, kansas state university, manhattan, ks 66506, usa 7 bsonicmill, 7500 bluewater road nw, albuquerque, nm 87121, usa 8 9 abstract 10 11 advanced ceramic. Jamestown, ny 14701 phone 7166652340 or 8007666606 fax 7166652480 revised may 2002 page 1 abstract a presentation describing the theory of ultrasonics and how ultrasonic technology is applied to precision cleaning. The method is employed to machine hard and brittle materials which are either electrically conducting or nonconducting. During ultrasonic machining, the metal removal is achieved by a high frequency eddy currents b high frequency sound waves c hammering action of abrasive particles d rubbing action between tool and workpiece 2. Principle of ultrasonic machining during one strike, the tool moves down from its most upper remote position with a starting speed at zero, then it speeds up to finally. Index termscavitation machining, hydrodynamic, ultrasonic, abrasive particle. Ultrasonic machining usm is the removal of material by the abrading action of. The transducer is driven by suitable signal generator followed by power amplifier.
The most important is labelled ultrasonic machining, by which is meant conventional ultrasonic machining, that is, the use of hammeraction tools with abrasive for cutting brittle materials. Neppiras until recently ultrasonic machining meant the hammer action of a tool tip which drives an abrasive into the workpiece and cuts out a hole in its own image. This machining process comes into existence in 1950 for finishing edm surface. Ultrasonic sensor is a sensor that works on principle similar to radar or sonar. Lecture series on manufacturing processes ii by prof.
Wallace says the typical use of this machine would be conventional metalcutting most of the time, with the ultrasonic head loaded into the spindle for the parts and operations benefitting most from this capability. Therefore, there is a 36 crucial need for reliable and costeffective machining pro37 cesses for advanced ceramics. Oct 22, 2008 lecture series on manufacturing processes ii by prof. Wedm process is based on the conventional edm sparking phenomenon utilizing the widely accepted noncontact technique of material removal. In the present paper, an experimental study of the ultrasonicbased depassivation process and its benefits related to an ecm proces are presented and discussed.
Ultrasonic technology poised for advance into general machining. This lowstress process translates into high reliability for your critical applications. The figure shows the ultrasonic machining operation. Advantages and disadvantages of ultrasonic machining process. If they strike an object, then they are reflected back as echo signals to the sensor, which itself computes the distance to the target based on the timespan between emitting the signal and. It comprises of a tool mounted on a rotary spindle attached to a piezoelectric transducer to produce the rotary and ultrasonic motion. Ultrasonic machining usm main parts, working principle. Working principle ultrasonic sensor series sistem komputer b. Not effected by material property, such as pressure environments, viscosity and specific gravity. The fundamental principles of stationary ultrasonic machining, the material removal mechanisms involved, proposed models for estimation of. Ultrasonic machining experiments were then carried out to machine alumina, zirconia, quartz, sodalime glass, ferrite and lif. Usm is a versatile machining process as far as properties of materials are concerned. Ultrasonic machining offers an effective alternative for ultra precision machining of hard and brittle materials due to its unique characteristics. Ultrasonic enhancement of an electrochemical machining.
Apr 15, 20 ultrasonic machining introduction ultrasonic machining is a non traditionalmechanical means of uniform stock materialremoval processit is applicable to both conductive andnonconductive materials. Unlike other nontraditional processes such as laser beam, and electrical discharge machining, etc. Ultrasonic machining introduction ultrasonic machining is a nontraditionalmechanical means of uniform stock materialremoval processit is applicable to both conductive andnonconductive materials. Ultrasonic machining, or strictly speaking the ultrasonic vibration machining, is a subtraction manufacturing process that removes material from the surface of a.
Theory of series inductance matching to transducer at pre. Download ultrasonic machining process pdf at the end of the article. Miyan ram 1709653 1 introduction ultrasonic machining usm is the removal of hard and brittle materials using an axially oscillating tool at ultrasonic frequencies 1820 khz during that oscillation, the abrasive slurry of b4c or sic is continuously fed into the machining zone between a soft tool brass or steel and the workpiece. In micro usm workpiece which is placed on the workpiece table vibrates at ultrasonic frequency 40 khz. A patented decoupling layer in special material is used to decouple the ultrasonics to the air an acoustically thin medium. Research on the machining principle and experinment of. A new nontraditional machining method using cavitation process. It is one of the types of nontraditional machining methods which produces circular, noncircular holes of very small size is ultrasonic machining method. Its principle is to make the toolworkpiece interaction a microscopically nonmonotonic process to facilitate chip separation and to reduce machining forces. Ultrasonic machining, or strictly speaking the ultrasonic vibration machining, is a subtraction manufacturing process that removes material from the surface of a part through high frequency, low amplitude vibrations of a tool against the material surface in the presence of fine abrasive particles. Jamestown, ny 14701 phone 7166652340 or 8007666606 fax 7166652480 revised may 2002 page 1 abstract a presentation describing the theory of ultrasonics and how ultrasonic technology is.
The experiment compared this ultrasonic machining process with the common machining process in. If it is possible, then what are the principles under the material removal process and what types of factors should be considered and studied further. Analysis of the mechanism of material removal by usm process indicates that it may sometimes be called ultrasonic grinding usg working principle of ultrasonic machining. Locating principle and locators free download as powerpoint presentation. This basic principle lies at the heart of the ultrasonic measurement technology and is illustrated in the equation. These propagate in the air at the velocity of sound. The process is a little like milling and a little like grinding, but ultimately different from both of these methods. Ultrasonic machining usm also called as ultrasonic vibration machining is a machining process in which material is removed from the surface of a part by low amplitude and high frequency vibration of a tool against surface of material in the presence of abrasive particles. Locating principle and locators machining industrial. The ultrasonic machine tool is equipped with a 42,000rpm spindle that accommodates a machining centers toolholder and cutting tool. The second approach is known under term of ultrasonic assisted machining uam. Today we will learn about ultrasonic machining, principle, working, equipments, application, advantages and disadvantages with its diagram. Ultrasonic machining is a nonconventional machining process. Therefore, ultrasonic sensor can be used to measure distance.
The vibration exciter, a magnetostrictive transducer 1, is fixed to the body 2 of the acoustic head using the shoulder 3 and the thin walled cup 4. As the distance to an object is determined by measuring the time of flight and not by the intensity of the sound, ultrasonic sensors are excellent at suppressing background interference. Ultrasonic machining is a nontraditional process, in which abrasives contained in a slurry are driven against the work by a tool oscillating at low amplitude 25100 microns and high frequency 1530 khz. Working principle and performance of wire electrical. Rotary ultrasonic machining rum is a non traditional machining process that combines the material removal mechanisms of diamond grinding and ultrasonic machining. Wu yb, niu jt, fujimoto m et al 20 fundamental machining characteristics of ultrasonic assisted turning of titanium alloy ti6al4v. Most grinding processes involve a work tool making direct contact with a work piece in order to gouge material away. Wire edmprinciple, process parameters, surface finish and machining accuracy, applications. A comparative study on ultrasonic machining of hard and brittle.
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