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Ultrasonic Machining: Principle of USM

Ultrasonic machining is a process where a tool vibrates at high frequency and is brought close to a workpiece with abrasive particles in between. The vibrations transmit high velocity to the abrasive particles, causing them to impact the workpiece surface and fracture it, removing material. Electrical power is converted to mechanical vibrations in the tool tip via a transducer. As the tool vibrates in an abrasive slurry between the tool and workpiece, the impacts remove small particles of material from even very hard and brittle surfaces with a good finish and accuracy.

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mahammad kamaluddeen
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259 views

Ultrasonic Machining: Principle of USM

Ultrasonic machining is a process where a tool vibrates at high frequency and is brought close to a workpiece with abrasive particles in between. The vibrations transmit high velocity to the abrasive particles, causing them to impact the workpiece surface and fracture it, removing material. Electrical power is converted to mechanical vibrations in the tool tip via a transducer. As the tool vibrates in an abrasive slurry between the tool and workpiece, the impacts remove small particles of material from even very hard and brittle surfaces with a good finish and accuracy.

Uploaded by

mahammad kamaluddeen
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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ULTRASONIC MACHINING

Principle of USM
Ultrasonic machining is based on, when a tool vibrating
at a high frequency is brought to closer to the work
piece with abrasive particles in between them, the
vibrating energy of tool can make the abrasive particles
to strike the workpiece with a great velocity. The
impacts of the abrasive particles fracture the hard work
surface resulting in the removal of material from the
workpiece.
USM operation
 USM process begins with the of low-frequency electrical
power to a high frequency electrical signal, which is
then fed to a transducer.
 The transducer converts the high frequency signal to
high frequency mechanical vibrations and transmitted
to tool tip via intermediate connecting parts.

 The tool, which is having the same shape as the cavity


to be machined, vibrates at a very high frequency in the
abrasive slurry pumped between the tool-work
interfaces.

 The vibration of tool transmits a high velocity to


abrasive particles, and as a result, the abrasive particles
strike the workpiece with great force.

 This impact fractures the hard and the brittle work


surface resulting in the removal of material in the form
of small wear particles. The abrasive slurry flowing at
the cutting zone carries away the fractured particles.

 The tool is pressed against the workpiece by applying a


slight force, while the abrasive slurry is being pumped in
at low pressures till the operation is completed.
ADVANTAGES
1. Very hard and brittle materials can be machined
easily.
2. The operation is noiseless.
3. Low cost.
4. Good surface finish and accurate profiles can be
generated.
5. No heat is generated in the process and hence
mechanical properties of the workpiece can be
maintained.

DISADVANTAGES
1. Metal removal rate is slow.
2. High initial investment.
3. High cost of the tool.
4. Difficult to machine softer material.
5. High power is consumed.
6. Chances of tool wear after certain period.
7. Abrasive slurry must be replaced periodically.
APPLICATIONS
1. Tool and die making.
2. In industry.
3. Cutting threads on metals and non-metals.
4. Machining glass, ceramics and tungsten.
5. Machining gems, diamonds, and stones.

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