It is employed to Hard or brittle materials ( both conductive and non conductive) having hardness Usually greater than 40RC. Ultrasonic machining process can be used for a) Conductors b) Insulators c) Metals d) All of the mentioned View Answer. Working on machines is not hazardous, provided care is taken to shield ultrasonic radiations from falling on the body. As the machines perform several techniques like: It consists of an electromechanical transducer connected to the AC supply. Ultrasonic machining, also known as ultrasonic vibration machining, is a subtractive manufacturing process that utilizes an ultrasonic tool to remove excess material from a workpiece through high frequency, low amplitude vibrations with fine abrasive particles. An abrasive gun is used to supply an abrasive slurry, which is a mixture of abrasive grain and the water in between tool-workpiece interface under a definite pressure. Unlike other manufacturing techniques, the ultrasonic machining process has unique benefits. The transducer converts an electrical signal to a mechanical signal whereas electromechanical transducer used to generates mechanical vibration. Ultrasonic machining is changing the manufacturing industries with its superlative performance. With suitable workpieces and reasonable interface design, watertight and airtight can be achieved, and the inconvenience caused by the use of auxiliary products can be eliminated, and efficient and clean welding can be realized. This chapter presents USM and rotary ultrasonic machining (RUM), including definitions, machine elements, input variables and their effects, applications, and … Our main goal is to provide you quality notes, updates, and much more stuff free of cost. Ultrasonic machining is the non-conventional machining process and generally, it is preferred for hard and brittle material preferably having the hardness above 40 HRClike semiconductor, glass, quartz, ceramic, silicon, germanium, ferrite,etc. These high velocity abrasive particles remove metal by brittle fracture or erosion from work piece. Aluminum oxide, Silicon carbide, Boron carbide are used as an abrasive particle in this slurry. Ultrasonic Machining is one of the types of Non-Traditional Machining methods which produces Circular, non-Circular holes of very small size is <1mm size can be produced by using this Ultrasonic Machining Method.. The tool has the same shape as the cavity to be machined. It uses a shaped tool, high frequency mechanical motion and abrasive slurry The term ultrasonic describes a vibratory wave having frequency larger than upper Frequency limit of human ear. Ultrasonic machining (USM) is a nontraditional mechanical machining process and can be used in many applications. That’s the only way we can improve. Ultrasonic machining is a non-traditional machining process. 9.2.1 The USM process Plasma arc machining b. Ultrasonic Machining c. iii. The Impact force arising out of the vibration of the tool end and the flow of abrasive slurry causing thousand of microscopic grains to remove from work material by abrasion. The design of this site was heavily, heavily inspired by, http://www.nitc.ac.in/dept/me/jagadeesha/mev303/Chapter_3_USM.pdf, https://www.sciencedirect.com/science/article/pii/S0890695597000369, Electron Beam Welding: Definition, Construction, Working, Applications, Advantages, and Disadvantages [Notes with PDF], Extrusion Process: Definition, Working Principle, Types, Applications, Advantages, and Disadvantages [Notes with PDF], Die Casting: Definition, Process, Types, Defects and Remedies, Applications, Advantages, Disadvantages [With PDF]. When the AC power is supplied with high frequency, the transducer starts vibrating longitudinally by magnetostriction, which is transmitted to the penetrating tool through a mechanical focusing device called Velocity transformer. This is essential. The machining operation is simple and requires less time. The tool is usually made from materials such as soft steels and nickel. – Machining ceramics, carbides, glass, precious stones, and hardened steels, – Create microelectromechanical system components such as micro-structured glass wafers, – Manufacture parts with high precision and tolerance. Slurry of abrasive and water Vibration frequency f ~ 19 - 25 kHz Amplitude, a ~ 10 – 50 μm Force, F Horn Tool Work Fig. The tool is made of soft ductile material like copper or brass, soft steel or stainless steel. This process is best suited for brittle materials. It also does not need to change the temperature. – Idea choice for ceramic matrix composites, glass, quartz, diamonds, PCD, etc. • Used in machining of dies for wire drawing, punching and blanking operations • USM can perform machining operations like drilling, grinding and milling operations on all materials which can be treated suitably with abrasives. Most grinding processes involve a work tool making direct contact with a work piece in order to gouge material away. Ultrasonic machining is also suitable for machining of hard and brittle materials including Glass, Sapphire, Ferrite, PCD, Piezo-ceramics, Quartz, CVD Silicon Carbide and Bio-Ceramics, etc. 9.2.1 briefly depicts the USM process. Electrical discharge Machining c. Electrochemical Machining d. Plasma arc machining (Ans:d) 34. Ultrasonic Machining: Definition, Parts, Working, Advantages, Disadvantages, Applications [With PDF]. Abstract:- Ultrasonic Machining is a mechanical material removal process that makes use of ultrasonic waves and abrasive slurry to remove the material from the workpiece. Ultrasonic machining is a subtractive 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. In which of the following processes, a nozzle is used? The tool travels vertically or orthogonal to the surface of the part at amplitudes of 0.05 to 0.125 mm. In this machining process a focus stream of abrasive particles are forces to impinge on work piece at high velocity. Ultrasonic Machining is mainly used to machine hard and brittle materials with low ductility. The device for converting any type of energy into ultrasonic waves is the ultrasonic transducer. The ultrasonic machining process can be employed to machine precision micro-features, circular and non-circular micro-holes and blind micro-cavities. This process is best suited for brittle materials.4. 1) Welding method: The welding head vibrating at ultra-high frequency of ultrasonic waves under a moderate pressure causes the frictional heat of the joint surfaces of the two plastics to be instantaneously melted and joined. $(".your-captcha .wpcf7-not-valid-tip").html("Incorrect"); Ultrasonic Machining Process description. a. In ultrasonic machining, a liquid filled with abrasive material flows through over the work piece, and the work tool vibrates against the abrasives. This Welding Process was first developed in 1949 by Karl-Heinz Steigerwald who was a German physicist. Answer: d Explanation: Ultrasonic machining is more versatile and can be used for the metal as well as non metal. Since laser machining is a thermal process, heat-affected damage does occur and can have a negative impact on the end use, especially in high-reliability applications. Ultrasonic Machining (USM) is changing the manufacturing Now this process is used in many industries to remove metal due to its lower cost, no heat generation, and effective machining. Grinding the brittle materials.4. Today in this article I am going to give you an in-depth overview of Electron Beam Welding Machine. The power consumption of ultrasonic machining is 0.1 W-h/mm 3 for glass and about 5 W-h/mm 3 for hard alloys. Despite all this, ultrasonic machining also has some shortcomings. The process was first developed in 1950s and was originally used for finishing EDM surfaces. The particles used in the abrasive fluid are usually boron carbide or silicon carbide as they are rigid than others. The process integrates well with semiconductor and MEMS Machined features can be aligned to previously patterned, machined, or etched substrates. Also known as ultrasonic vibration machining, it’s a manufacturing process that’s used to remove material from a workpiece through the use of high-frequency vibrations combined with particles. 2) Ri… The material to be processed will affect the selection of the machining process. 1. Ultrasonic machining (USM) using loose abrasive particles suspended in a liquid slurry for material removal is considered an effective method for manufacturing these materials. Copyright ©Junying Metal Manufacturing Co., Limited, What is Ultrasonic Machining – Ultrasonic Machining Principle, Advantages and Application | CNCLATHING, Aluminum 6061-T6 vs 7075-T6 – Difference Between 6061-T6 and 7075-T6 | CNCLATHING, Difference Between T6 and T651 – Aluminum Tempers Designation System Explain | CNCLATHING, How to Calculate CNC Machining Time – CNC Machining Cycle Time Calculation | CNCLATHING, Different Types of Screws and Their Uses – Understanding Wood Screws, Machine Screws and More | CNCLATHING, Compare Different Fasteners: Difference Between Bolt, Screw, Rivet and Nut | CNCLATHING. The main reason why this machining process is used in the manufacturing area is because it evolves less heat in the process. In ultrasonic machining, the tool moves vertically or orthogonal to the surface of the part and fluctuate at the ultrasonic frequencies, the vibrations generated by the tool will project micro-sized abrasive particles to the part at a high speed, the particles mix with water or other liquids to form a slurry, which flowing between tool and workpiece, helps to grind away material from the surface of the piece. Advantages of Ultrasonic Machining (USM): (a) This process can be used for drilling of circular or non-circular holes in very hard materials like stones, carbides, ceramics and … The applications of Ultrasonic Machining are: The advantages of Ultrasonic Machining are: Here are some disadvantages of Ultrasonic Machining: So this is the overview of Ultrasonic machining I hope you like this article, to read this type of Manufacturing stuff keeps visiting LearnMechanica.Com. USM is grouped under the mechanical group NTM processes. 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