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[1] HISTORY
1927:
Wood and Loomis Noted Prospects of using High Frequency Sound Waves for
Machining
1945:
History of USM began with a Patent granted to an American Engineer Lewis
Balamuth
1951-52: First Report on Equipment and Technology
1954:
First Machine Tool using Ultra Sonic Principle Constructed
Initially Used as Finishing Operation for the Electro Spark Machined Components
Can be used to Machine Hard and/or Brittle Materials having Rockwell Hardness on C
scale > 40
Can be used for both Electrically Conducting and Non-Conducting Materials
Non-Chemical and Non-Thermal in Nature Materials are Not Altered Chemically and
Metallurgically
Characterized by Low MRR and no or Very Little Surface Damage to the Work Material
[4.1] ACOUSTIC HEAD: To Produce and Propagate the Vibrations in the Tool. The Most Important
Part
[4.1.1] POWER SUPPLY: A High Power Sine-Wave Generator
Converts Low Frequency Electrical Power (50 Hz) to High
Frequency (~20 kHz)
Electrical Power
Offers Control Over both Frequency and Power of the Generated
Signal
Power Range can be 40 W to 2,400 W
[4.1.2] TRANSDUCER: To Convert High Frequency Electrical Energy into High Frequency
Mechanical Energy
Can be Based on TWO Different Principles: Piezoelectric and
Magnetostrictive
Piezoelectric or
Electrostrictive Transducers
Magnetostrictive Transducers
Piezoelectric
Materials:
Zirconate Titanate
Quartz,
Lead
Catenoidal
Concentrator is simply a Convergent Wave Guide for Designed Amplitude at its Far End
It is Made Resonating to Obtain Sufficient Amplitude of Vibrations
[Achievable Amplitude of Vibrations from Transducer does not Exceed 3-5 Microns
while at Tool End it should be 5-75 microns]
The Concentrator Becomes a Volume Resonator Tuned to the Same Frequency which Produces the Best
Condition for Maximum Power Transfer
Maximum Change in Dimension (Elongation/Contraction) Corresponds to a Magetostrictor Length Equal to the Half
of the Wavelength (l = 0.5), Therefore Length of Propagation is made Half Wavelength or Multiple of it
C 1 E
; where
f
f
Speed of Sound in the Magetostrictor Material (m/s)
Frequency of Changes in the Magnetic Field (s 1 )
Young's M odulus of Magnetostrictive Material (MPa)
Density of Magnetostrictive Material (kg/m 3 )
Wavelength
C
f
E
1
2l
l Length of the Magnetostrictor
[4.1.4] TOOL:
To Minimize the Tool Wear, it Should be Constructed of Strong but Ductile Material
Commonly Used Materials: Brass, Mild Steel, Stainless Steel
For Hole Drilling: Music wire, Stainless Steel, or Hypodermic Needles
Harder the Tool Material Faster the Tool Wear Rate
Depending upon the Abrasive Used, Workpiece, and Tool Material the MRR/TWR can Range from 1 to 100
More Wear at the End, Wear at Sides is 10%
Aluminum Wears 10 times and Brass Wears 5 times Faster than Steel Tools
Area of the Tool Tip Influences the Penetration Rate, Smaller the Contact Area Better the Abrasive Flow under
Tool and Higher the Penetration Rate
Tool Should be as Short and Rigid as Possible
For Hollow Tools, the Internal Contour Should be Parallel to the External one to Ensure Uniform Wear
Thickness of any Wall or Projection should be at Least Five Times the Abrasive Grain Size and should Not be
Less than 0.5 to 0.8 mm
Longer Flow Path Gives Inefficient Cutting due to Poor Scavenging
Most Desirable Method of Attaching the Tool to the Toolholder is Silver Brazing as it Minimizes the Fatigue
Problem Associated with Screw Attachment
Allowances should be Provided to Compensate for the Overcut Produced by the Process
Diameter of the Tool = Desired Diameter 2 Abrasive Particle Size
Diameter of the Circle Circumscribed about the Tool should not be More than 1.5 to 2 times diameter of End of
Concentrator
[4.2] Feeding Unit: To Apply the Working Force during the Machining Operation
To Carry Abrasive to the Cutting Zone and Wash Away the Worn Abrasives and Swarf from the Cutting Zone
Liquid Help in Material Removal due to Cavitation Effect during Return Stroke of the Tool
Liquid Helps in Evenly Distribution of Abrasive Particles into the Working Gap
Acts as Coolant
MRR f
[6.3] ABRASIVE PARTICLE SIZE (d): Existence of Optimum Size of Abrasive Particles has been
Confirmed by
Neppiras and Foskett [1956] Experimentally: Non-Linear Relationship
Nair and Ghosh [1985]; and Wang and Rajurkar [1996] Theoretically
Goetze [1956]: Linear Relationship
[6.4] STATIC FEED FORCE (Fs): An Optimum Value Exists Because Initially MRR Increases with an
Increase in Static Feed Force but after a Certain Limit MRR Starts Decreasing due to Crushing
and Impaired Motion of Abrasive Particles.
[6.5] ABRASIVE SLURRY CONCENTRATION (C av): MRR Improves with Slurry Concentration but
Saturation Occurs at 30 40%.
[6.6] INDENTATION RATIO i.e. Hardness Ratio of Workpiece and Tool ():MRR Decreases
with Indentation Ratio
MRR Also Increases with Higher Brittleness of Workpiece Material, Slurry Pressure, and Decrease in Carrier Fluid Viscosity
Capability/Characteristics
Surface Roughness [CLA in m]
0.4 - 1.6
12.5 25.0
0.025
Drilling
Capabilities
Cutting
Capabilities
Economic
Aspects
Common Value/Range
Chemical Damage
NO
Mechanical Damage
25
Thermal Damage
NO
0.13 3.18
Aspect Ratio
0.1 2.5
1.5 51
5.0
10
900
0.07
1.5 51.0
0.025 25.0
Low
Low
Medium
Medium
Parameter
Common Value/Range
Tool Material
Abrasives
Medium
Tool-Workpiece Gap
25 40 m
Process
Paramete
rs
Vibration Amplitude
5 100
Vibration Frequency
10 40 kHz
Volumetric Concentration
of Abrasive Particles in the
Slurry
5 50%
4.5 45 N
[10.1] ADVANTAGES:
Possibly Safest among all the Conventional and Non-Conventional Machining
Processes as there is No Cutting, Voltage, Burning, Chemical Reaction, or
Dangerous Mechanical Motions
USM Can Even Not Cut Skin due to its Ductility
No Effect on Material Structure
[10.2] LIMITATIONS:
Low MRR
Tool Wear
Not Suitable for Soft Materials
Small Aspect Ratio (up to 2.5 for accurate holes)
Bottom of a Cavity Cannot be Machined Flat as very Few Active Grains Come Under the
Tool
Tendency of the Drilled Hole to Break Out at the Bottom due to Static Load and Vibration
Amplitude
Poor Machining Accuracy: Accuracy of the Machined Component may be Lost due to
Lateral Vibrations
Slurry may Pollute the Environment
Possible Sticking of Abrasive Particles may Necessitate Cleaning Operation