Ultrasonic machining is a subtractive manufacturing technique that removes material from a part’s surface. The tool moves at amplitudes of 0.05 to 0.125 mm (0.002 to 0.005 in.) either vertically or orthogonally to the part’s surface.
The technique is used to remove material from the workpiece by producing a large number of tiny vibrations. Fine abrasive particles are applied to the material’s surface during the entire process.
Well, in this reading, we’ll explore what ultrasonic machining is, its applications, parts, diagrams, types, and how it works. The advantages and disadvantages of ultrasonic machining will also be discussed.
Let’s begin!
Learn about Machine Design with this detailed guide!
What is Ultrasonic Machining?
Ultrasonic machining is a subtractive manufacturing technique that removes material from a part’s surface. The tool moves at amplitudes of 0.05 to 0.125 mm (0.002 to 0.005 in.) either vertically or orthogonally to the part’s surface.
It uses high-frequency, low-amplitude vibrations of a tool on the material surface in the presence of small abrasive particles.
Ultrasonic machining is an unconventional technique of manufacturing that works with small abrasive particles and low-amplitude tool vibrations to remove material on a workpiece surface. This technique reduces brittle fracture during hammering by using a ductile tool material, which makes it easier to remove material precisely and machine delicate components.
The tool moves vertically or orthogonally to the part’s surface at amplitudes ranging from 0.05 to 0.125 mm (0.002 to 0.005 in.). A fine mixture of abrasive grains and water creates a slurry, which is then applied to both the part and the tooltip.
Grain sizes typically range from 100 to 1000, with smaller grains resulting in smoother surface finishes. Ultrasonic vibration machining is commonly employed for brittle and high-hardness materials because of the mechanics of microcracking.
In addition, the tool generates vibrations that propel micro-sized particles towards the workpiece, which are combined with water or other liquids to form a slurry. Upon activation, these particles are propelled rapidly toward the surface of the workpiece, enabling their abrasive properties to effectively remove material.
Applications
Ultrasonic machining is an advanced machining technique that specializes in processing non-conductive ceramics and produces ceramic components with precise form and intricate patterns.
The process ensures precise results and little material loss while machining sensitive materials, as it offers accuracy and consistency in die manufacturing and is used to create dies for wire drawing, punching, and blanking operations.
Ultrasonic machining enables dental professionals to make holes of different forms painlessly, ensuring an accurate and cozy treatment.
The machining process is employed for the precise grinding of materials such as quartz, glass, and ceramics, offering superior surface finishes and dimensional precision.
Ultrasonic machining is used to cut industrial diamonds, accomplishing exact and complicated cuts of expensive and resilient materials.
Die fabrication is also an application of ultrasonic machining, including the production of molds for casting, embossing, and forming processes. This accuracy is used in the fabrication of micro-electro-mechanical system components, including micro-structured glass wafers, where diamonds are shaped to specific forms.
You should also learn about cutting tools with this detailed guide!
Parts of an Ultrasonic Machining
The power source, velocity transformer, tool, abrasive slurry, electro-mechanical transducer, abrasive slurry, and workpiece itself make up the several tools used in ultrasonic machining.
A power supply is used to transform electrical supply into a high-frequency electrical supply with tiny vibration amplitudes, usually between 20 and 40 kHz.
The transducer’s vibration is enhanced by the velocity transformer, which makes it ideal for powering the tool during cutting.
an abrasive particle is used to remove material from the workpiece; They are used to strike or percuss the ductile tool. This is because ultrasonic frequencies accelerate the hammering pace; tool wear and fatigue resistance are essential.
A slurry of abrasive particles is used so that the machining can be effective. It is placed between the tool and the workpiece, and new abrasives are continually delivered by a water jet.
The workpiece is also a part of the process, where an electromechanical transducer ensures control and accuracy by converting electrical energy into mechanical vibrations.
The cannon is used to guarantee a steady supply of new abrasives at controlled pressure by delivering abrasive slurry through a water medium. This method is perfect for precisely cutting complex 3D structures out of brittle, non-conductive materials like ceramics.
Learn about laser beam machining with this detailed guide!
Diagram
Types of Ultrasonic Machining
The common types of ultrasonic machining are rotary ultrasonic vibration machining and chemical-assisted ultrasonic vibration machining.
Rotary Ultrasonic Machining
Rotary ultrasonic vibration machining (RUM) serves as an innovative manufacturing process used for the machining of advanced materials, including ceramics and alloys such as glass, quartz, structural ceramics, titanium alloys, alumina, and silicon carbide. The tool’s surface is embedded with diamonds, enabling the precise grinding of the part.
Researchers are actively engaged in improving the process at the micro-level, enabling the machine to function in a similar way to a milling machine, which will improve the precision of the machining process.
Chemical-Assisted Ultrasonic Machining
Chemical-assisted ultrasonic machining (CUSM) improves surface quality and increases the material removal rate for glass and ceramic materials when compared to conventional techniques. The application of an acidic solution such as hydrofluoric acid enhances machining characteristics.
The entrance profile diameter may exhibit a slight increase as a result of the enhanced chemical reactivity associated with the new slurry selection. It is essential to carefully choose the acid content to maintain user safety and ensure product quality.
You should also learn about Non-Traditional Machining with this detailed guide!
How Does Ultrasonic Machining Work?
A slurry of abrasive particles is placed between a ductile tool and the workpiece, creating a 0.25 mm gap in the process of ultrasonic machining. With a slightly tapered tool, the slurry efficiently removes material, allowing for material scrubbing and straight holes.
The frequency of the vibrating tool, the size of the abrasive slurry grains, the stiffness, and the viscosity all affect how long a person stays on the ultrasonic machine.
Different factors, such as the carrier fluid’s viscosity, frequency, amplitude, and the size and concentration of the abrasives, influence the material removal rate (MRR) in ultrasonic machining.
Additional impacts from higher abrasive concentrations raise MRR until momentum loss happens, which lowers MRR. Likewise, bigger abrasive sizes provide bigger impact areas, but going above a specific size reduces the abrasives’ speed. Ultrasonic Machining is ranked between Electrochemical Machining (ECM) and Electrical Discharge Machining (EDM) in terms of material removal rate.
Also learn about electrochemical machining with this detailed guide!
Advantages and Disadvantages of Ultrasonic Machining
Benefits:
- The machining process is ideal for non-metallic materials with low electrical conductivity due to low heat generation and compatibility with other technologies.
- It produces clean and accurate surfaces, eliminating burrs and distortion.
- Ultrasonic machining is compatible with other cutting-edge technologies for increased functionality and adaptability.
- The process is user-friendly, as its design allows both experienced and novice workers to operate the equipment.
Drawbacks
- Small material removal rate, high energy requirement, and challenges in machining delicate materials.
- Minimal slurry flow can hinder deep hole drilling and efficient material removal.
- Abrasive particles in slurry shorten tool life, increasing tool wear and requiring frequent tool replacements.
Conclusion
Ultrasonic Machining is a non-traditional machining process that uses high-frequency vibrations and abrasive slurry to precisely remove material from hard and brittle workpieces like ceramics, glass, and carbides.
It is especially valuable for intricate shapes and delicate components where conventional machining may fail. Although slower than traditional methods, This machining process offers high accuracy, no thermal damage, and minimal residual stress, making it ideal for precision engineering applications.
You should also learn about lathe machine with this detailed guide!
FAQs on Ultrasonic Machining
What is ultrasonic machining?
USM is a subtractive manufacturing process where material is removed from a workpiece using a vibrating tool and abrasive slurry at ultrasonic frequencies (typically 20 kHz or more).
What materials can be machined using ultrasonic machining?
USM is ideal for brittle and hard materials like glass, ceramics, quartz, carbides, and semiconductor materials.
What are the main components of an ultrasonic machining setup?
The key components include the power supply, transducer, booster, horn (tool holder), abrasive slurry system, and workpiece.
What are the advantages of Ultrasonic machining?
- No heat-affected zone (no thermal damage)
- High precision for brittle materials
- Can machine complex and delicate shapes
- Minimal tool wear
What are the limitations of ultrasonic machining?
- Slow material removal rate
- Not suitable for soft or ductile materials
- Requires frequent slurry maintenance
How is USM different from EDM or laser machining?
Unlike EDM or laser machining, USM is a mechanical process and does not generate heat, making it safer for heat-sensitive materials.
Is tool wear a concern in ultrasonic machining?
Tool wear is relatively low because the tool doesn’t directly cut the material; instead, it transmits ultrasonic vibrations to the abrasive particles.