Maulana Azad National Institute of

Technology
Branch : PIE
Sem : (V)
Subject : Metal cutting (PI-305)
Topic : Ultrasonic Machining
 Content
1. Introduction of USM
2. Schematic diagram
3. Principle & Working
4. Mechanism
5. Mathematic Design for MMR
6. Process parameter & effect
7. USM system & subsystem
8. Application
9. Advantages & disadvantages
10. Summary
11. Quiz , Problem & solution
12. References
 Ultrasonic machining
Introduction

Ultrasonic machining is a non-traditional

mechanical means of uniform stock material
removal process

It is applicable to both conductive and

nonconductive materials.

Particularly suited for very hard and/or

brittle materials such as
graphite, glass, carbide, and ceramics.
 Various work samples machined by USM

1- The first picture on the left is a plastic sample that has inner grooves that are machined using
USM.
2- The Second picture (in the middle is a plastic sample that has complex details on the surface
3- The third picture is a coin with the grooving done by USM
 Systematic diagram

Force
feed
motion
Transducer
Acoustichead/toolholder
Workpiece
Slurry to machining
zone

Slurry pump
Return slurry
Slurry tank
 Principal and working
The process is performed by a cutting tool, which
oscillates at high frequency, typically 20-40 kHz, in
abrasive slurry.

The tool is gradually fed with a uniform force.

The high-speed reciprocations of the tool drive the
abrasive grains across a small gap against the
workpiece .

The impact of the abrasive is the energy principally

responsible for material removal in the form of
small wear particles that are carried away by the
abrasive slurry.

The tool material, being tough and ductile, wears out at

a much slower rate.

The shape of the tool corresponds to the shape to be

produced in the workpiece.
 Mechanism

The basic components to the cutting

action are believed to be

33

4
 4. Mathematical design for MRR

Hemispherical material
removed due to brittle

material removal per abrasive grit is given as

indentation depth in the work

material is characterised by

If at any moment of time, there are an average ‘n’ of grits and the tool is vibrating at a
frequency ‘f’ then material removal rate can be expressed as

1
the impulse of force on the tool and work would be balanced. Thus total impulse on the tool
can be expressed as
Again, if the flow strength of work material is taken as

If ‘A’ is total surface area of the tool facing the

2 workpiece, then volume of
abrasive slurry of one grit thickness is
If n is the number of grits then the total volume of n grits is

Thus the concentration of abrasive grits in the slurry is related as follows:

Now it is expected that indentation would be
inversely proportional to the flow
strength then,

3
5.
Process Parameters and their Effects
The process parameters which govern the ultrasonic machining process have
been identified and the same are listed below along with material parameters

Amplitude of vibration (a) - 15- 50 um

Frequency of vibration (f)-19-25kHz

Feed force (F)

Abrasive material – Al2O3
- SiC Feed pressure (p)
- B4C
- Boronslicarbide Abrasive size-15-150um
- Diamond

Contact area of the tool - A

Volume concentration of abrasive in slurry - C

the effect of parameters on MRR.
 USM System
Subsystems of USM System

A C

E D
A

• The power supply is a sine-wave generator

• The user can control over both the frequency and
power of the generated signal.
• It converts low-frequency (50/60 Hz) power to high-
frequency (10-15 kHz) power
• Supply to the transducer for conversion into
mechanical motion.
 B

• Two types of transducers are used in USM to convert the supplied energy to
mechanical motion.
• They are based on two different principles of operation
- Magnetostriction
- Piezoelectricity

• When the material is placed in a sufficiently strong magnetic field, the

magnetic moments of the domains rotate into the direction of the
applied magnetic field and become parallel to it.
• During this process the material expands or contracts, until all the
domains have become parallel to one another.
• very common magnetostrictive composite is the amorphous
alloy Fe81Si3.5B13.5C2 with its trade name Metglas 2605SC
• Such as quartz or lead,zirconate,titanate, generate a small electric current when
compressed.
• Conversely, when an electric current is applied, the material increases minutely
in size.
• When the current is removed, the material instantly returns to its original shape.
 C

• Its function is to increase the tool vibration amplitude and to match

the vibrator to the acoustic load.
• It must be constructed of a material with good acoustic properties
and be highly resistant to fatigue cracking.

Monel and titanium

have good acoustic
properties and are often
used together with
stainless steel, which is
cheaper.
The acoustic head can be of different shape like

• Tapered or conical
• Exponential
• Stepped

 The acoustic head is the

most complicated part of
the machine.
 It must provide a static
force, as well as the high
frequency vibration
Exponential tapered stepped
Different Horns used in USM
 D

• Tools should be constructed from relatively ductile materials.

• The harder the tool material, the faster its wear rate will be.
• It is important to realize that finishing or polishing operations on the
tools are sometimes necessary because their surface finish will be
reproduced in the workpiece.

• The geometry of the tool generally corresponds to the geometry of the cut
to be made,
• Because of the overcut, tools are slightly smaller than the desired hole or
cavity
• Tool and toolholder are often attached by silver brazing.
E
• Abrasive Slurry
- common types of abrasive
- boron carbide (B4C) good in general, but expensive
- silicon carbide (SiC) glass, germanium, ceramics
- corundum (Al2O3)
- diamond (used for rubies , etc)
- boron silicon-carbide (10% more abrasive than B4C)

• liquid
- water most common
- benzene
- glycerol
- oils
- high viscosity decreases MMR
 Applications
It is mainly used for
(1) drilling
(2) grinding,
(3) Profiling
(4) coining
(5) piercing of dies
(6) welding operations on all materials which can be treated suitably by
abrasives.
(7) Used for machining hard and brittle metallic alloys, semiconductors,
glass, ceramics, carbides etc.
(8) Used for machining round, square, irregular shaped holes and surface
impressions.
 Advantages of USM
• Machining any materials regardless of their conductivity

• USM apply to machining semi-conductor such as

silicon, germanium etc.

• USM is suitable to precise machining brittle material.

• USM does not produce electric, thermal, chemical abnormal

surface.

• Can drill circular or non-circular holes in very hard materials

• Less stress because of its non-thermal characteristics

 Disadvantages of USM

• USM has low material removal rate. (3-15mm3/min)

• Tool wears fast in USM.

• Machining area and depth is restraint in USM.

 Summary of USM
• Mechanics of material removal - brittle fracture caused by impact of
abrasive grains due to vibrating at high frequency
• Medium - slurry
• Abrasives: B4C; SiC; Al2O3; diamond; 100-800 grit size
• Vibration freq. 15-30 KHz, amplitude 25-100 micro m
• Tool material soft steel , ductile
• Critical parameters - frequency, amplitude, tool material, grit size, abrasive
material, feed force, slurry concentration, slurry viscosity
• Material application - metals and alloys (particularly hard and brittle),
semiconductors, nonmetals, e.g., glass and ceramics
• Shape application - round and irregular holes, impressions
• Limitations - very low mrr, tool wear, depth of holes, and cavities small.
 Quiz test
1. Which of the following material is not generally machined by USM
(i) Copper (ii) Glass (iii) Silicon (iv) Germanium
1- (i)
2. Tool in USM is generally made of
(i) Glass (ii) Ceramic (iii) Carbides (iv) Steel
2 – (iv)
3. Increasing volume concentration of abrasive in slurry would affect MRR in
the following manner
(i) increase MRR (ii) decrease MRR (iii) would not change MRR (iv) initially
decrease and then increase MRR

3 – (i)
4. USM can be classified as the following type of non-traditional process
(i) Electrical (ii) optical (iii) mechanical (iv) chemical
4 – (iii)
 Problems

Soln. to Prob. 1
 References

• Module 9 Non-conventional machining IIT

Kharagpur
• http://nptel.iitm.ac.in/
• http://en.wikipedia.org/wiki/Ultrasonic_mach
ining
• www.youtube.com/watch?v=XXm4Cf_N9CA
• http://www.bullentech.com/animation