INTRODUCTION TO ULTRASONIC MACHINING

1. PRESENTATION
ON
ULTRA SONIC MACHINING
Submitted To:-
Er. Parmod Kumar
(Mech. Dept. , M M U SADOPUR)
Submitted By:-
PARAG PRIYANK
75114037

2. 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 work
piece, aided by an abrasive slurry that flows freely between the
workpiece and the tool. It differs from most other machining
operations because very little heat is produced. The tool never
contacts the workpiece and as a result the grinding pressure is
rarely more than 2 pounds, which makes this operation perfect
for machining extremely hard and brittle materials, such as glass,
sapphire, ruby, diamond, and ceramics.

3. ELEMENTS OF PROCESS:-
 WORK MATERIAL
 TOOL CONE & TOOL TIP
 ABRASSIVE SLURRY

4. WORK MATERIAL:-
 There is no limitation of this process in terms of machining type
of materials
 Due to non-contact type it can be used for hard & brittle
materials, diamond, glass, sapphire and ceramics which are also
poor conductors of electricity.
 Chip forming materials can be used for machining
 The only one concern is that the material being machined must
not dissolve in slurry media or react with it anyhow.

5. TOOL TIP & TOOL CONE:-
 The tool cone amplifies & focuses the mechanical
energy produced by transducer & imparts this to
workpiece so that energy utilization is maximum.
 The horn mechanically modifies vibratory energy to
give required force-amplitude ratio.
 To operate efficiently horn must be tuned within few
kilo cycles/sec.
 Titanium is good material. Alloy steel, stainless steel
also fall in the same category.

6. Abrasive Slurry
 Boron is the most expensive abrasive material but is the best
suited for cutting steel & precious stones so Boron carbide is
used.
 Silicon carbide is also used in maximum applications.
 Diamond are nicely cut by diamond powders which provides good
accuracy.
 Boron –silicon-carbide is a new abrasive which has an 12%
greater power as compared to boron carbide.
 For 0.5 micron surface roughness 280 grit size of abrasive is
required and for 0.2, 800 grit is required.

8. DESIGN OF CUTTING TOOL
 Tough ductile materials are preferred in USM; mild steel is
usually used as the tool material.
 The mass of the tool used in USM is important because too
large a mass will absorb ultrasonic energy and reduce
machining efficiency.
 Tools should be designed to resist fatigue failure.
 Also, proper stroke of the tools is critical to avoid chipping
and scratching which may accelerate failure in service.
 Horn used in USM equipment usually feature a drilled and
tapped hole in their end faces to facilitate mounting of the
tool holder. Horns are usually made of brass, steel, titanium,
or aluminum