ULTRASONIC MACHINING

ULTRASONIC MACHINING:-
                                                 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.
                                                                                                                                                                                                          The tool travels vertically or orthogonal to the surface of the part at amplitudes of 0.05 to 0.125 mm (0.002 to 0.005 in.). The fine abrasive grains are mixed with water to form a slurry that is distributed across the part and the tip of the tool. 

                                        Typical grain sizes of the abrasive material range from 100 to 1000, where smaller grains (higher grain number) produce smoother surface finishes .....

Abstract

Rotary ultrasonic machining (RUM) has been investigated in machining of brittle, ductile, as well as composite materials. Ultrasonic vibration amplitude, as one of the most important input variables, affects almost all the output variables in RUM. Numerous investigations on measuring ultrasonic vibration amplitude without RUM machining have been reported. In recent years, ultrasonic vibration amplitude measurement with RUM of ductile materials has been investigated. It is found that the ultrasonic vibration amplitude with RUM was different from that without RUM under the same input variables. RUM is primarily used in machining of brittle materials through brittle fracture removal. With this reason, the method for measuring ultrasonic vibration amplitude in RUM of ductile materials is not feasible for measuring that in RUM of brittle materials. However, there are no reported methods for measuring ultrasonic vibration amplitude in RUM of brittle materials. In this study, ultrasonic vibration amplitude in RUM of brittle materials is investigated by establishing a mechanistic amplitude model through cutting force. Pilot experiments are conducted to validate the calculation model. The results show that there are no significant differences between amplitude values calculated by model and those obtained from experimental investigations. The model can provide a relationship between ultrasonic vibration amplitude and input variables, which is a foundation for building models to predict other output variables in RUM.

Ultrasonic MachiningHard Brittle Materials  and Other Challenges

As we all know machine tool, cutting tool, automation and software technology are all advancing. However, one other area of progress affecting manufacturers in ever-greater numbers is the advance of material technology. Machine shops are increasingly being challenged by advanced materials, including composites and hard metals, many of which are difficult to machine.

Traditionally used with abrasive cutting tools, ultrasonic machining is now an option for defined-cutting-edge milling and drilling tools as well. With these tools, ultrasonic’s advantages extend to its aid to chip breaking

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