Deeptanshu Pandey presented on ultrasonic machining. Ultrasonic machining is a non-traditional process that uses tool vibration at ultrasonic frequencies along with an abrasive slurry to erode material. It is well-suited for hard and brittle materials. The document discussed the principles, components, parameters, applications and advantages of ultrasonic machining, including how the abrasive particles remove material through impact erosion during the downstroke of tool vibration. In summary, ultrasonic machining uses high frequency tool vibration and an abrasive slurry to precisely machine hard, brittle materials through a brittle fracture material removal process.

1. SHRI RAMSWAROOP MEMORIAL GROUP OFSHRI RAMSWAROOP MEMORIAL GROUP OF
PROFESSIONAL COLLEGESPROFESSIONAL COLLEGES
TEWRIGANJ 227-105TEWRIGANJ 227-105
SEMINAR ON ULTRASONIC MACHINING
PRESENTED BY:
DEEPTANSHU PANDEY
1612240067
Deeptanshu Pandey (M.E.-53)

2. CONVENTIONAL MACHINING PROCESS
 Generally macroscopic chip formation by shear
deformation
 Material removal takes place due to application of
cutting forces – energy domain can be classified as
mechanical
 Cutting tool is harder than work piece at room
temperature as well as under machining conditions
Deeptanshu Pandey (M.E.-53)

3. CONVENTIONAL MACHINING PROCESS
Deeptanshu Pandey (M.E.-53)

4. COMPARISON
Conventional Non Conventional
Chip Formation
Generally macroscopic chip
formation by shear
deformation.
Material removal may occur
with chip formation or even
no chip formation may take
place. For example in AJM,
chips are of microscopic size
and in case of
Electrochemical machining
material removal occurs due
to electrochemical
dissolution at atomic level
Tool There may be a physical tool
present. for example a
cutting tool in a Lathe
Machine,
There may not be a physical
tool present. For example in
laser jet machining,
machining is carried out by
laser beam. However in
Electrochemical Machining
there is a physical tool that is
very much required for
machining.
Deeptanshu Pandey (M.E.-53)

5. Conventional Non Conventional
Characteristic of Tool
Cutting tool is harder than
work piece at room
temperature as well as
under machining conditions
There may not be a physical
tool present. For example in
laser jet machining,
machining is carried out by
laser beam. However in
Electrochemical Machining
there is a physical tool that is
very much required for
machining.
Material Removal Process
Material removal takes
place due to application of
cutting forces – energy
domain can be classified as
mechanical
Mostly NTM processes do not
necessarily use mechanical
energy to provide material
removal. They use different
energy domains to provide
machining. For example, in
USM, AJM, WJM mechanical
energy is used to machine
material, whereas in ECM
electrochemical dissolution
constitutes material
removal.
Deeptanshu Pandey (M.E.-53)

6. Conventional Non Conventional
Tool Contact
Conventional machining
involves the direct contact
of tool and work –piece
Whereas unconventional
machining does not require
the direct contact of tool
and work piece.
Surface Finish
Lower accuracy and
surface finish.
Higher accuracy and
surface finish.
Deeptanshu Pandey (M.E.-53)

7. Conventional Non Conventional
Material Economy
Suitable for every type of
material economically.
Not Suitable for every type
of material economically
Tool Life
Tool life is less due to high
surface contact and wear.
Tool life is more
Material Wastage Higher waste of material
due to high wear.
Lower waste of material due
to low or no wear.
Noise Level Noisy operation mostly
cause sound pollutions
Quieter operation mostly no
sound pollutions are
produced.
Cost Lower capital cost Higher Capital Cost
Deeptanshu Pandey (M.E.-53)

8. Conventional Non Conventional
Equipment Setup Easy set-up of equipment. Complex set-up equipment.
Operator level Skilled or un-skilled operator
may required
Skilled operator required.
Process Generally they are manual
to operate.
Generally they are fully
automated process.
Efficiency They cannot be used to
produce prototype parts
very efficiently and
economically.
Can be used to produce
prototype parts very
efficiently And
economically.
Spare Parts Easily Available Not so easily available
Deeptanshu Pandey (M.E.-53)

9. ULTRASONIC MACHINING
 Introduction.
 Equipment.
 Tool Materials and Tool Size and Abrasive Slurry.
 Cutting tool system design
 Effect of parameter: Effect of amplitude and frequency and vibration.
 Effect of abrasive grain diameter.
 Effect of applied static load.
 Effect of slurry, tool and work material.
 USM process characteristics: Material removal rate, tool wear, Accuracy,
surface finish, applications,
 Advantages & Disadvantages of USM.
Deeptanshu Pandey (M.E.-53)

10. INTRODUCTION
 What is the Difference between Frequency,
Wavelength and Amplitude?
 Frequency tells us how many waves pass through a
point at a second.
 Wavelength tells us the length of those waves.
 Amplitude tells us how big the wave is.
 In USM, abrasives contained in a slurry are driven
against the work by a tool oscillating at low amplitude
(25-100 microns) and high frequency (15-30 kHz).
Deeptanshu Pandey (M.E.-53)

11. PRINCIPLE
 The machining zone (between the tool and the work
piece) is flooded with hard abrasive particles
generally in the form of water based slurry.
 As the tool vibrates over the work piece, abrasive
particles acts as indenter and indent both work and
tool material .
 Abrasive particles , as they indent , the work material
would remove the material from both tool and work
piece.
 In Ultrasonic machining material removal is due to
crack initiation, propagation and brittle fracture of
material.
Deeptanshu Pandey (M.E.-53)

12. Ultrasonic Machining-
Introduction
 Ultrasonic machining is a non-traditional
mechanical means of uniform stock
material removal process
 It is applicable to both conductive and
nonconductive materials.
 Particularly suited for very hard and/or
brittle materials such as graphite, glass,
carbide, and ceramics.
Deeptanshu Pandey (M.E.-53)

13. 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.
 It uses formed tools, vibrations
of high frequency and a
suitable abrasive slurry mix.
 Ultrasonic range is possible
with the help of piezoelectric
materials.
 Frequency > 20,000 Hz.
Deeptanshu Pandey (M.E.-53)

14. Schematic Diagram
Deeptanshu Pandey (M.E.-53)

15. Process
 Impact erosion process - abrasive
particles.
 Cutting abrasive particles in the slurry
(fluid).
 Material removal abrading action
“shaped tool” and the workpiece.
Deeptanshu Pandey (M.E.-53)

16. Working Principle
 The process is performed by a
cutting tool, which oscillates at
high frequency, typically 20-40
kHz, in abrasive slurry.
 The tool is gradually fed with a
uniform force.
 The high-speed reciprocations
of the tool drive the abrasive
grains across a small gap
against the workpiece .
 The impact of the abrasive is
the energy principally
responsible for material
removal in the form of small
wear particles that are carried
away by the abrasive slurry.
 The shape of the tool
corresponds to the shape to be
produced in the workpiece.Deeptanshu Pandey (M.E.-53)

17. Mechanism for material
removal
 Occurs when the abrasive particles, suspended in the
slurry between the tool and workpiece, are struck by
the downstroke of the vibration tool.
 The impact propels the particles across the cutting
gap, hammering them into the surface of both tool
and workpiece. Collapse of the cavitation bubbles in
the abrasive suspension results in very high local
pressures.
 Under the action of the associated shock waves on
the abrasive particles, microcracks are generated at
the interface of the workpiece – brittle fracture.
 The brittle fracture lead to chipping of particles from
the workpiece.
Deeptanshu Pandey (M.E.-53)

18. USM system components
1. Power supply
2. Transducer
3. Tool holder
4. Tool
5. Abrasive slurry
Deeptanshu Pandey (M.E.-53)

19. USM system components
1.Transducer
 Piezoelectric transducers utilize crystals like quartz whose dimensions
alter when being subjected to electrostatic fields.
 The charge is directionally proportional to the applied voltage.
 To obtain high amplitude vibrations the length of the crystal must be
matched to the frequency of the generator which produces resonant
conditions.
Deeptanshu Pandey (M.E.-53)

20. USM system component
2. Abrasive
 Abrasive Slurry
- common types of abrasive
- Boron carbide (B4C) good in general, but expensive
- Silicon carbide (SiC) glass, germanium, ceramics
- Corundum (Al2O3)
- Diamond (used for rubies , etc)
- Boron silicon-carbide (10% more abrasive than B4C)
 Liquid
- Water most common
- Benzene
- Glycerol
- Oils
- High viscosity decreases MRR
Deeptanshu Pandey (M.E.-53)

21. USM system component
3. Tool Holder/Acoustic head
 The shape of the tool holder is cylindrical or conical, or a
modified cone which helps in magnifying the tool tip
vibrations.
 Its function is to increase the tool vibration amplitude and to
match the vibrator to the acoustic load. Therefore it must be
constructed of a material with good acoustic properties and
be highly resistant to fatigue cracking.
 Monel and titanium have good acoustic properties and are
often used together with stainless steel, which is cheaper.
Deeptanshu Pandey (M.E.-53)
Exponential tapered
stepped

22. USM system component
4. Tool
 Tool material should be tough and ductile. Low carbon steels and stainless
steels give good performance.
 Tools are usually 25 mm long ; its size is equal to the hole size minus twice the
size of abrasives.
 Mass of tool should be minimum possible so that it does not absorb the
ultrasonic energy.
 It is important to realize that finishing or polishing operations on the tools are
sometimes necessary because their surface finish will be reproduced in the
workpiece.
 Tool and toolholder are often attached by silver brazing.
Deeptanshu Pandey (M.E.-53)

23. Process Parameters
1. Amplitude of vibration (a) - 15- 50 um.) - 15- 50 um.
2. Frequency of vibration (f)-19-25kHz
3. Feed force (F)
4. Feed pressure (p)
5. Abrasive size-15-150um
6. Contact area of the tool – A
7. Volume concentration of abrasive in slurry - C
Deeptanshu Pandey (M.E.-53)

24. Process Parameters
Deeptanshu Pandey (M.E.-53)

25. Application
It is mainly used for
(1) drilling
(2) grinding,
(3) Profiling
(4) coining
(5) piercing of dies
(6) welding operations on all materials which can be treated
suitably by abrasives.
(7) Used for machining hard and brittle metallic alloys,
semiconductors, glass, ceramics, carbides etc.
(8) Used for machining round, square, irregular shaped holes
and surface impressions.
Deeptanshu Pandey (M.E.-53)

26. Advantages
 Machining any materials regardless of their conductivity
 USM apply to machining semi-conductor such as silicon,
germanium etc.
 USM is suitable to precise machining brittle material.
 USM does not produce electric, thermal, chemical
abnormal surface.
 Can drill circular or non-circular holes in very hard
materials
 Less stress because of its non-thermal characteristics
Deeptanshu Pandey (M.E.-53)

27. Disadvantages
 USM has low material removal rate. (3-
15mm3/min)
 Tool wears fast in USM.
 Machining area and depth is restraint in USM.
Deeptanshu Pandey (M.E.-53)

28. References
 Google.com
 Wikipedia.org
 Studymafia.org
 Pptplanet.com
Deeptanshu Pandey (M.E.-53)

29. Thank You
Deeptanshu Pandey (M.E.-53)