Ultrasonic machining usm openlearn open university. Ultrasonic machining usm main parts, working principle. Ultrasonic machining process optimization by cuckoo search. Ultrasonic machining usm machining materials scribd. 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. The process produces little or no surfacesubsurface damage or impose particular stress regimes. This machining process comes into existence in 1950 for finishing edm surface. Ultrasonic machining from the technology data exchange linked to trusted tde listed vendors. The machining medium is solid grains suspended in an abrasive slurry in the former,while a fluid is employed in the wjm process.
Ultrasonic machining usm nontraditional machining ultrasonic machining non traditional means of uniform stock. Usm is mechanical material removal process or an abrasive process used to erode holes or cavities on hard or brittle workpiece by using shaped tools, high frequency mechanical motion and an abrasive slurry. Rotary ultrasonic machining rum is a mechanical type of nontraditional hybrid machining process that has been utilized potentially to machine a wide range of latest and difficultto machine materials, including ductile, hard and brittle, ceramics, composites, etc. 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.
This article lists the major ultrasonic components that are similar to both rotary usm and ultrasonic impact grinding. Recent advancement on ultrasonic micro machining usmm. 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. When very frequency vibrations are applied on to the tool, the. Ultrasonic machining usm is a mechanical material removal process used to erode holes and cavities in hard or brittle workpieces by using shaped tools, highfrequency mechanical motion, and an. Ultrasonic vibration machining can only be used on materials with a hardness value of at least 45 hrc rockwell hardness. 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. On this channel you can get education and knowledge for general issues and topics. It is one of the types of nontraditional machining methods which produces circular, noncircular holes of very small size is ultrasonic machining method. Tool oscillates with high frequency, and the continuous abrasive slurry is. Ultrasonic machining, also known as ultrasonic impact grinding, is a machining operation in which a vibrating tool oscillating at ultrasonic frequencies is used to remove material from the workpiece, aided by an abrasive slurry that flows freely between the workpiece and the tool.
Ultrasonic machining process usm, water jet machining. The figure shows the ultrasonic machining operation. Working of ultrasonic machining usm process parameters introduction ultrasonic machining is a nontraditional machining process. Ultrasonic machining usm is a mechanical material removal process used to erode holes and cavities in hard or brittle workpieces by using shaped tools, highfrequency mechanical motion, and an abrasive slurry. Ultrasonic machining usm is the removal of material by the abrading action of gritloaded liquid slurry circulating between the workpiece and a tool vibrating perpendicular to the workface at a frequency above the audible range. Usm machined features is greatly influenced by the cutting force variations.
The ultrasonic technology from dmg mori enables the economical machining of complex workpiece geometries in demanding hightech materials like e. The method is employed to machine hard and brittle materials which are either electrically conducting or nonconducting. The erosion takes place by the abrasive particles which are carried by a liquid medium in the from of a slurry. Ultrasonic machining is nontraditional machining process which is used to machine brittle and hard material. Pdf process characteristics in ultrasonic machining. Ultrasonic machining is a contemporary manufacturing method usually employed for processing materials with higher hardnessbrittleness such as quartz, semiconductor materials, ceramics etc. Pdf ultrasonic machining is the oldest form of machining process which can be. The workpiece is held in a tank of slurry containing abrasive particles, the slurry is injected into the space between a vibrating tool and stationary workpiece.
Introduction 2 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 b 4 c or sic is continuously fed into the machining zone between a soft tool brass or steel and the workpiece. Ultrasonic machining menawarkan solusi untuk mempermudah dalam proses permesinan bahan yang keras, getas, rapuh. Ultrasonic machining usm updated tuesday 6th march 2018. Ultrasonic machining usm is another alternative method for manufacturing both conductive and nonconductive hard and brittle materials. Ultrasonic machining usm free download as pdf file. So this is the overview of ultrasonic machining i hope you like this article, to read this type of manufacturing stuff keeps visiting learnmechanica. Usm offers a solution to the expanding need for machining brittle materials.
Ultrasonic machining introduction ultrasonic machining is a nontraditionalmechanical means of uniform stock materialremoval processit is applicable to both conductive andnonconductive materials. Abrasive jet machining ajm construction and working advantages and limitations of ultrasonic machining usm advantages. Usm is used for machining hard and brittle materials, which are poor conductors of electricity and thus cannot be processed by electrochemical machining. Download ultrasonic machining process pdf at the end of the article. 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. The machined surface produced by ultrasonic machining is found to be free from any surface defects heat affected zone, cracks, recast layer, etc.
It is also known as ultrasonic impact grinding is an operation that involves a vibrating tool fluctuating the ultrasonic frequencies in. Introduction ultrasonic machining is a nontraditional machining process. Unlike other nonconventional machining methods such as laser beam and electrical discharge machining, usm does not thermally damage the workpiece. It is also known as ultrasonic impact grinding is an operation that involves a vibrating tool fluctuating the ultrasonic frequencies in order to remove the material from the work piece. A comparative study on ultrasonic machining of hard and. Ultrasonic machining usm, using shaped tools, highfrequency mechanical motion, and abrasive slurry is effective for materials of extreme hardness or brittleness. In order to meet the challenges posed by the machining of the hardto machine and brittle materials whether conductive or nonconductive, the technique of ultrasonic machining usm has been developed in the field of machining technology. 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.
The ultrasonic machining usm process consists of two methods, namely, ultrasonic impact grinding and rotary usm. Ultrasonic machining usm is the removal of material by the abrading action of. Ultrasonic machining process optimization by cuckoo search and chicken swarm optimization algorithms. Ultrasonic machining,direct impact,abrasive grains,material removal rate. In this process abrasives contained in the slurry are driven against the work by a tool oscillating at low amplitude 25100 microns and high frequency 1530 khz. Ultrasonic machining is a mechanical type nontraditional machining process. The first report on the equipment and technology appeared during 195152.
High precision machining on a wide spectrum of hard and brittle material can be done by usm, which are otherwise difficult to machine using the conventional method. Material is abraded away until a mirror image of the tool is cut into the workpiece. Ultrasonic machining usm applications advantages and. In contrast, ultrasonic machining usm is a nonthermal process which does not rely on a conductive workpiece and is suited to the machining of ceramic materials. Recent development on ultrasonic micro machining usmm process has been highlighted and discussed in details with different types of ultrasonic micro machining usmm set up and material removal mechanism. Ultrasonic machining usm and ultrasonic machining tool. The ultrasonic machining usm process has been analyzed in the present study to obtain the desired process responses by optimizing machining parameters using. Ultrasonic machining is a mechanical material removal process that uses formed tools, vibration of high frequency and abrasive slurry mix. Sometimes referred to as ultrasonic impact grinding uig or vibration cutting, the um process can be used to generate. The use of ultrasonics in machining was first proposed by l. In this process, the slurry is supplied to the gap between. In contrast, ultrasonic machining um or usm is a nonthermal, nonchemical and nonelectrical machining process that leaves the chemical composition, material microstructure and physical properties of the workpiece unchanged.
Ultrasonic machining usm and waterjet machining wjm are typical examples of single action, mechanical non traditional machining processes. It is known as a total mechanical process without suffering from heat or chemical effects, so usm would not thermally damage the machining objects or appear to cause significant levels of residual stress and. Ultrasonic vibrationassisted uva machining is a group of machining processes during which ultrasonic vibration is applied on either the cutting tool or the workpiece. When very frequency vibrations are applied on to the. The usm process consists of tool made of ductile and tough material.
Ultrasonic machining usm mesin ini digunakan untuk memotong, mengukir, melubangi baik lubang yang langsung maupun lubang setengah. Match listi machining process with listii associated medium and select the correct answer using the codes. Ultrasonic machining usm is an effective method for machining of hard brittle materials. Pdf ultrasonic machining usm vinu murugaraj academia. Ultrasonic vibrationassisted uva machining of composites. By 1954, the machine tools, using the ultrasonic principle, had been designed and constructed. The introduction of abrasives to the fluid jet enhances the. Ultrasonic machining usm working principles in this process the material of the workpiece is removed by the repetitive impact actions of abrasive particles. Particularly suited for very hard andorbrittle materials such asgraphite, glass, carbide, and. China automation ultrasonic machining manufacturers and.
Another perspective of rum is to consider rum as a hybrid process, which combines two. Ultrasonic machining usm is a mechanical material removal process used to erode holes and cavities in hard or brittle. In ultrasonic machining, a tool of desired shape vibrates at an ultrasonic frequency 19 25 khz with an. The fundamental principles of stationary ultrasonic machining, the material removal mechanisms involved, proposed models for. Micro ultrasonic machining micro usm, is one of the efficient material removal processes especially suitable for the micromachining of hard and brittle materials. Working of ultrasonic machining usm process parameters. It also provides schematic representations of the components used in rotary usm and ultrasonic impact grinding. Stationary or conventional ultrasonic machining usm accomplishes the removal of material by the abrading action of a gritloaded slurry, circulating between. Ultrasonic machining is a nontraditional machining process. The tool travels vertically or orthogonal to the surface of the part at amplitudes of 0. Today we will learn about ultrasonic machining, principle, working, equipments, application, advantages and disadvantages with its diagram. Contohnya mineral, polycrystalline, keramik, kaca, pcd, alumina, kuarsa, piezoceramic, kristal dan sebagainya.
Usm is grouped under the mechanical group ntm processes. Usm offers a solution to the expanding need for machining. This chapter presents uva machining processes that have been reported to machine three types of composite materials. Ultrasonic machining usm is a mechanical material removal process used to erode holes and cavities in hard or brittle work pieces by using shaped tools.
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