The tool has oscillated at ultrasonic frequencies as well as rotated. Ultrasonic machining is a special processing that uses ultrasonic frequency as a tool for small amplitude vibration and slamming the surface of the workpiece by the slamming action of the abrasive which is free from the liquid between the workpiece, which is abbreviated as usm. Chemicalassisted ultrasonic machining of glass sciencedirect. Today we will learn about ultrasonic machining, principle, working, equipments, application, advantages and disadvantages with its diagram. 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. No previous reports have been found in the literature to experimentally investigate the response of the bk7 glass to rotary ultrasonic drilling. Parametric optimization of ultrasonic machining process using gravitational search and fireworks algorithms. This work was the first to demonstrate the crack formation mechanisms during ultrasonic machining with different abrasive particles using smoothed particle hydrodynamics, which is significant for improving the machining performance of the ultrasonic machining process. Recent advancement on ultrasonic micro machining usmm. Conventional machining processes for the machining of fibre composite materials often show potential of optimization due to their high degree of tool wear, frequently inadequate component quality and insufficient feed rates. Usm offers a solution to the expanding need for machining. The ultrasonic machining usm process has been analyzed in the present study to obtain the desired process responses by optimizing machining parameters using. Its principle is to make the toolworkpiece interaction a microscopically nonmonotonic process to facilitate chip separation and to reduce machining forces. The machining medium is solid grains suspended in an abrasive slurry in the former,while a fluid is employed in the wjm process.
Particularly suited for very hard andorbrittle materials such asgraphite, glass, carbide, and ceramics. Ultrasonic machining usm openlearn open university. Their rotary ultrasonic machining process works much the same way except that the ultrasonic motion from the converter is amplified and transmitted to. Machining ultrasonic machining the industrial resource. Working of ultrasonic machining usm process parameters.
Ultrasonic machining is a contemporary manufacturing method usually employed for processing materials with higher hardnessbrittleness such as quartz, semiconductor materials, ceramics etc. Jun 22, 2010 introduction the technology of high power ultrasonics, already extensively applied at ewi in the fields of welding, solderingbrazing and additive manufacturing, is now being extended to the field of ultrasonic machining. A study on the effect of main process parameters of rotary. Study of parameters of ultrasonic machining ethesis national page 21. Ultrasonic machining by ms shikha kashyap 1 ultrasonic machining. Pdf process characteristics in ultrasonic machining.
High speed machining hsm seminar and ppt with pdf report. Although manufacturing technologies are well developed for materials like metals and their alloys, considerable problems still exist in the fabrication of hard and brittle materials including ceramics and glass. But in a more recent move with this technology, dmg mori personnel in the u. If brought into contact with ferrous materials, a diffusion process takes place that accounts for a life time of the tool ultrasonic vibration to the tool together with the right process parameters allows for the diamond to constantly loose contact with the ferrous material and to recover from upcoming diffusion. Mechanical machining ultrasonic machining usm and waterjet machining wjm are typical examples of single action, mechanical non traditional machining processes. Recently a new development in ultrasonic machining has taken place in which a tool impregnated with diamond dust is used and no slurry is used. Nagarjuna published on 20191 download full article with reference data and citations.
By 1954, the machine tools, using the ultrasonic principle, had been designed and constructed. Jul 22, 20 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 technology poised for advance into general machining. The jamming leads a decrease of material removal efficiency and finally increases the machining force. Ppt ultrasonic machining by ms shikha kashyap powerpoint.
Ultrasonic machining usm and ultrasonic machining tool. Ultrasonic machining process optimization by cuckoo search and chicken swarm optimization algorithms. Rotary ultrasonic machining rum is a mechanical type nontraditional hybrid machining process which has been utilized potentially to machine a wide range of latest and difficulttomachine. Ultrasonic machining parts, working, advantages full notes. Ultrasonic machining in ultrasonic machining, a tool of desired shape vibrates at an ultrasonic frequency 19 25 khz with an amplitude of around 15 50. Ultrasonic machining usm is a mechanical metal removal process for machining hard and brittle materials such as glass, ceramics, quartz, silicon etc. View ultrasonic machining ppts online, safely and virus free. Tongtai t51usa ultrasonic machining center cutting tool. Generally tool is pressed down with a feed force f. It uses formed tools, vibrations of high frequency and a suitable abrasive slurry mix. Ultrasonic machining is a mechanical material removal process that uses formed tools, vibration of high frequency and abrasive slurry mix.
Ultrasonic machining centers for optics and ceramics manufacturing. This machining process comes into existence in 1950 for finishing edm surface. Ultrasonic machining is changing the manufacturing industries with its superlative performance. The ultrasonic motion from the converter is amplified and transmitted to the horn and cutting tool. Slicing, coining, dicing, lapping, engraving, deburring, broaching, boring and trepanning operations are also practical.
Single point cutting, multipoint cutting, electrical discharge machining edm and electrochemical machining ecm. The resulting capability for finecontrol cnc machining of previously unmachinable materials arguably remains ultrasonic machining s most valuable application. Welcome to the premier industrial source for ultrasonic machining services. This article is a part of manupedia, a collection of information about some of the processes used to convert materials into useful objects. Ppt ultrasonic machining powerpoint presentation free to. Apr 15, 20 ultrasonic machining introduction ultrasonic machining is a nontraditionalmechanical means of uniform stock materialremoval processit is applicable to both conductive andnonconductive materials. Ultrasonic machining from the technology data exchange linked to trusted tde listed vendors. Processing capabilities of micro ultrasonic machining for hard and brittle materials. Ultrasonic machining has recently gained recognition as an influential process in the technology of cutting and shaping produce for which nonmechanical processes prove inadequate. Ultrasonic machining introduction ultrasonic machining is a. An attempt has been made to construct a micromodel for prediction of material removal rate in ultrasonic machining of titanium using dimensional analysis. Usm is mechanical material removal process or an abrasive process used to erode holes or cavities on hard or.
The tool is usually made from materials such as soft steels and nickel. A comprehensive description on ultrasonic machining. In rum, the basic material removal phenomenon of ultrasonic machining usm and. It is known as a process that aids betterknown methods such as drilling, turning and grinding. Ultrasonic machining is ultrasonic machining processes, as being developed and applied at ewi, consist of the. Adequate surface finish with stiff tolerances and dimensions can be achieved by ultrasonic micro machining usmm on hard and brittle materials. The term ultrasonic is used to describe vibrational waves having a frequency above the hearing range of normal human ear i. View and download powerpoint presentations on ultrasonic machining ppt. Ultrasonic machining is nontraditional machining process which is used to machine brittle and hard material. Ultrasonic machining is a mechanical material removal process that uses formed tools.
Process characteristics in ultrasonic machining ijert. Uniti introduction and ultrasonic machining uniti introduction and ultrasonic machining subject. Rotary ultrasonic machining for zircon oxide and many more 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. Ultrasonic vibrationassisted uva machining is a process which makes use of a microscale high frequency vibration applied to a cutting tool to improve the material removal effectiveness. China automation ultrasonic machining manufacturers and. Ultrasonic machining usm equipment elements and working.
Ultrasonic micro machining is the mechanical type non conventional micro machining process. Their superior physical and mechanical properties lead to long machining cycle and high production cost. It is one of the types of nontraditional machining methods which produces circular, noncircular holes of very small size is download ultrasonic machining process pdf at the end of the article. It is one of the types of nontraditional machining methods which produces circular, noncircular holes of very small size is ultrasonic machining method. I the machining medium is solid grains suspended in an abrasive slurry. Ultrasonic machining usm is a nonconventional mechanical material removal process generally associated with low material removal rates, however its application is not limited by the electrical or chemical characteristics of the workpiece materials. Find powerpoint presentations and slides using the power of, find free presentations research about ultrasonic machining ppt. Parts are burr free with no residual stresses or thermal effects.
Efficient ultrasonic machining of highend composite components. Generally the tool is pressed downward with a feed force, f. Sep, 2009 the optimal settings of parameters are determined through experiments planned, conducted, and analyzed using taguchi method. Download ultrasonic machining process pdf at the end of the article. This article presents the use of rotary ultrasonic machining process for drilling holes in bk7 glass. Manufacturing processes for android download apk free. In the present work, with the development of the higher power rotary ultrasonic machine tool, two kinds of ultrasonic face machining with free abrasives, namely, nonrotating ultrasonic machining with free abrasives nrusm and rotary ultrasonic machining with free abrasives rusm are designed and comparatively conducted for the red granite. Ultrasonic range is possible with the help of piezoelectric materials. The analytical solution of the free sonotrode vibrations. Usm is mechanical material removal process used to erode holes or cavities on hard or brittle work piece by using shaped tools, high frequency mechanical motion and an abrasive slurry. Modeling the material removal rate in ultrasonic machining of.
Ultrasonic technology poised for advance into general. Material removal mechanism of usmm is similar to macro ultrasonic machining process. The process was first developed in 1950s and was originally used for finishing edm surfaces. The material eligible for ultrasonic machining includes aluminum alloy, hardened steel, glass, and ceramic materials. The machining operation is simple and requires less time. Processing capabilities of micro ultrasonic machining for. Experience unprecedented machining efficiency with high performance ultrasonic milling, grinding, core drilling and lightweighting of optical glasses and ceramics. Ultrasonic machining, or strictly speaking the ultrasonic vibration machining, is a subtraction manufacturing process that. Usm is a versatile machining process as far as properties of materials are concerned.
Smoothed particle hydrodynamics simulation and experimental. Wallace says the typical use of this machine would be conventional metalcutting most of the time, with the ultrasonic head loaded into the spindle for the parts and operations benefitting most from this capability. Dec 09, 2017 11 points to know from ultrasonic machining process usm. Match listi machining process with listii associated medium and select the correct answer using the codes. 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. Their rotary ultrasonic machining process works much the same way except that the ultrasonic motion from the converter is amplified and transmitted to the rotary spindle.
Ultrasonic assisted machining is performed by applying a certain vibration to the cutting tool or to the workpiece to improve the tool life and surface properties in finishing process applications. Ultrasonic machining ppt with seminar report study mafia. The companies featured in the following listing offer a comprehensive range of ultrasonic machining services, as well as a variety of related products and services. With the ultrasonic machining device, the machining efficiency of the original spindle has been improved from three to five times. Mechanical machining i jet machining and ultrasonic machining usm are typical examples of single action, mechanical non traditional machining processes. View or download all content the institution has subscribed to. The experimental investigations take into account the effect of the key rotary ultrasonic machining input parameters including the ultrasonic power, spindle speed and feed rate on the output responses of cutting force, exit chipping, surface roughness, hole cylindricity and overcut errors, and surface integrity. Theoretical model for cutting force in rotary ultrasonic.
Ultrasonic machining is a nontraditional machining process, grouped under the mechanical group ntm processes. Burr free holes and slots in hard, brittle materials. When comparing to that of another nontraditional machining process the ultrasonic machining process is unique because of its suitability for the brittle material such as glass, ceramics, carbides, precious stones, hardened steels,etc. Pdf ultrasonic machining is the oldest form of machining process which can be used to machine brittle materials such as glass and. Ultrasonic machining centers take your machining capabilities to the next level, along with your bottom line, with optisonic. Process characteristics in ultrasonic machining written by tejaswi hegade, jnaneshwar r. The machined surface produced by ultrasonic machining is found to be free from any surface defects heat affected zone, cracks, recast layer, etc. Sinker ultrasonic processing changes high frequency electrical energy into mechanical motion. In ultrasonic machining, tool of desired shape vibrates at ultrasonic frequency 19 to 25 khz. Ultrasonic refers to waves of high frequency above the audible range of 20 khz.
However, the free particles generated by the milling process. Ultrasonic machining by ms shikha kashyap 1 ultrasonic machining ms shikha kashyap assistant professor dept of mechanical engineering the northcap university, gurgaon 2 ultrasonic machining. Schematic of ultrasonic machine tool usm is primarily targeted for the machining of hard and brittle materials dielectric or. Rotary ultrasonic machining or ultrasonic vibration assisted grinding has superior performance in machining hard and brittle materials, such as dental zirconia ceramics. The tool travels vertically or orthogonal to the surface of the part at amplitudes of. The application of ultrasonic vibration energy in the machining process provides many bene. Ultrasonic horn design for ultrasonic machining technologies. When very frequency vibrations are applied on to the tool, the. Electric discharge wire cutting process wire edm 14. Generally, an ebook can be downloaded in five minutes or less. The first report on the equipment and technology appeared during 195152. This process is used for drilling both circular and noncircular holes in very hard materials like carbide, ceramics, etc. Also, the process is limited, in its present form to the machine on surfaces of comparatively small size. The main reason why this machining process is used in the manufacturing area is because it evolves less heat in the process.
This technology first appeared as ultrasonic machining. Ultrasonic machining or usm nontraditional machining unconventional machining e4education for detail note visit. Best ultrasonic tool machining on different materials. 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. 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. Ultrasonic machining it is a mechanical material removal process, used to. Ultrasonic machining process optimization by cuckoo search. Ultrasonic machining is a nontraditional machining process. Ultrasonic machining is a mechanical type nontraditional machining process. Ultrasonic machining usm using loose abrasive particles suspended in.
However, there are few reports about cutting force modeling of rotary ultrasonic milling rum for dental ceramics, especially for cutting force model in feed direction. Rotary ultrasonic machining rum is a hybrid machining process that combines the material removal mechanisms of diamond grinding with ultrasonic more detailed. Ultrasonic machining process the tool present in the machine for cutting the materials is made from a soft material as compared to the work piece. 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 chemicalassisted ultrasonic machining process, which uses a low concentration hf solution for chemical effect, was developed to overcome the disadvantages of the conventional usm process, such as a low material removal rate and surface quality. Ultrasonic machining introduction ultrasonic machining is a nontraditionalmechanical means of uniform stock materialremoval processit is applicable to both conductive andnonconductive materials. 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.
An overview of ultrasonic machining and applications. The ultrasonic machining center is also a fully capable conventional machining center. Ultrasonic machining it is a mechanical material removal process, used to erode material in the form of fine holes and cavities in hard or brittle workpiece. 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. 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 difficulttomachine materials, including ductile, hard and brittle, ceramics, composites, etc. A free powerpoint ppt presentation displayed as a flash slide show on id. Nontraditional manufacturing processes chemical machining cm electrochemical machining ecm electrodischarge machining edm laser cutting ultrasonic machining usm a free powerpoint ppt presentation displayed as a flash slide show on. Ppt nontraditional manufacturing processes powerpoint. The t51usa adopts the 0imd controller with spindle speeds up to 20,000 rpm. 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. The use of ultrasonics in machining was first proposed by l. Effects the process parameters which govern the ultrasonic machining process. Ultrasonic machining free download as powerpoint presentation.
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