Ultrasonic Micro-machining
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This is all about Principle and working of Micro USM (ultrasonic machining) process along with MRR, advantages and working fields.
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Components and machine structure
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Conclusion
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This document provides information about an Unconventional Machining Processes course. It includes the course code, regulation, instructor details, course outcomes, modules, and learning outcomes. Specifically, it outlines Module I which provides an introduction to unconventional machining processes, including ultrasonic machining. It discusses the history, principles, setup, mechanisms, materials used, applications, and limitations of ultrasonic machining.
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1) Ultrasonic machining uses high frequency vibrations and abrasive particles to machine hard and brittle materials through microchipping.
2) Piezoelectric and magnetostrictive transducers are used to generate the ultrasonic vibrations, while abrasive slurry carries away debris from the cutting area.
3) Ultrasonic machining can drill holes, grind, profile and machine many hard materials like ceramics, glass, and carbides with precision tolerances.
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Micromachining is used to create micrometer-scale parts and devices. It is derived from traditional machining processes but operates on a smaller scale using less force. There are several micromachining processes including micro milling, laser ablation, etching, and lithography that use mechanical forces, lasers, or chemical reactions to shape materials like ceramics, metals, polymers, and silicon. Micromachining is used to fabricate components for microelectromechanical systems, integrated circuits, medical devices, and more.
Electrochemical+micromachining+(emm)
Electrochemical micromachining (EMM) is a non-traditional machining process that uses electrical and chemical energy for precision micro-machining of conductive materials. EMM involves anodic dissolution of workpiece material in an electrolyte solution between a tool electrode and workpiece electrode. EMM allows for machining of complex micro-scale geometries without thermal or mechanical stresses. The document describes the fundamentals, process parameters, applications and a demonstration EMM setup developed for micro-fabrication.
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Wire cut EDM uses a thin wire as the electrode to cut complex shapes into difficult-to-machine materials like tungsten carbide. The process involves using a CNC machine to move the workpiece near the vertically moving wire while a dielectric fluid flows between them. Electrical sparks erode small amounts of material from both the wire and workpiece, with the fluid flushing away debris. Key aspects that enable the precision process include a servo system to maintain a small gap, water-based dielectric fluid for initiating sparks and cooling, and characteristics of the consumable wire electrode.
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Ultrasonic Machining
1. Ultrasonic machining is a non-traditional machining process that uses a vibrating tool to remove material from a workpiece submerged in an abrasive slurry.
2. The tool vibrates at high frequency (typically 20-40 kHz) and is gradually fed into the workpiece. The abrasive grains in the slurry are driven across a small gap by the vibrating tool and impact the workpiece, removing small particles.
3. Ultrasonic machining can machine both conductive and non-conductive materials like ceramics and is well-suited for hard, brittle materials. Key factors that influence the material removal rate include vibration frequency and amplitude,
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This presentation contain discription about Fine finishing process of complex shape material which cannot be finished by normal processess. three type of finishing process has been described they are Abrasive flow machining, MAgnetic Abrasive Finishing, Magneto Rheological abrasive finishing.
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Electro Chemical Machining Process
Electrochemical machining (ECM) is a non-traditional machining process that removes metal by electrolysis rather than mechanical forces. In ECM, a tool acts as a cathode and the workpiece as an anode, and an electric current is passed through an electrolyte in the gap between them, chemically dissolving metal from the workpiece. ECM can machine hard metals and complex shapes more accurately than traditional machining. It provides a smooth surface finish with no mechanical forces or heat affecting the workpiece material. However, ECM requires an electrolyte solution, specialized equipment, and produces chemical waste, making it more expensive and less environmentally friendly than other processes.
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This document discusses electrochemical honing, which combines electrochemical dissolution and mechanical abrasion to machine conductive materials. It removes metal through an electrochemical process using an electrolyte and cathodic tool, while also using abrasive stones for mechanical material removal and surface finishing. This hybrid process allows for higher material removal rates than conventional honing or grinding. Electrochemical honing can achieve tight tolerances, good surface finishes, and shape and finish workpieces in a single process with minimal heat and stresses on the material.
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Microfabrication involves creating miniature structures and parts that are not visible to the naked eye and are between 1 micrometer and 1000 micrometers in size. Key microfabrication methods include micro machining and advanced nano finishing processes. Micro machining involves material removal at the micro/nano scale using processes like magnetic abrasive finishing, magnetorheological finishing, and diamond turning. These processes allow for high precision manufacturing of parts for applications like optics and microelectronics.
Hybrid machining
Hybrid manufacturing combines two or more non-traditional manufacturing processes. Electrochemical grinding combines electrochemical machining and grinding. It uses a grinding wheel and electrolytic fluid to remove material from a conductive workpiece. The process produces close tolerances and smooth surfaces. Key advantages are minimal wheel wear and ability to machine hard materials. Applications include machining difficult materials like carbides and composites. Future developments could improve efficiency and surface quality when machining advanced materials.
Electric discharge machining (edm)
Electric discharge machining (EDM) is a machining process that uses electrical sparks to erode metals. It works by maintaining a precise gap between an electrode tool and a metal workpiece submerged in a dielectric fluid. Repeated electrical sparks are generated to melt and vaporize small amounts of metal from both the tool and workpiece, allowing complex and hard-to-machine shapes to be produced. EDM can machine metals regardless of hardness and without mechanical force, giving it advantages over traditional machining methods for difficult-to-cut materials.
Abrasive flow machining (afm)
Abrasive flow machining is a finishing process that uses a semi-solid abrasive putty to remove small amounts of material from workpieces. The putty is forced through or across the workpiece using hydraulic pressure to deburr, radius, polish and perform other surface finishing operations. It is well suited for finishing metals, ceramics and plastics in a uniform and economical manner, though it is not used for heavy material removal due to its low material removal rate. The process involves selecting abrasive media based on the material and desired finish, and using tooling and pressure to direct the flow of media through restrictions in the workpiece.
Plasma Arc Machining process
Plasma arc machining uses ionized gas (plasma) to cut metals. It can cut materials that are difficult to cut with traditional techniques due to high thermal conductivity and oxidation resistance. The process involves generating a pilot arc to ignite the plasma and transferring the arc to the workpiece to melt and vaporize the metal, which is removed by the high-velocity gas. Plasma arc machining produces high-quality cuts at maximum productivity and is suitable for automated cutting applications.
Magnetorheological
This document discusses magnetorheological abrasive flow finishing (MRAFF), a process that uses a magnetorheological polishing fluid to precisely control finishing forces and achieve a final surface finish. An experimental setup was designed to study the process, consisting of MR polishing fluid cylinders, hydraulic actuators, an electromagnet, and workpiece fixture. Experiments showed no surface roughness change at zero magnetic field but improved surface finish at higher fields, as the MR fluid's viscosity changes with applied field strength. The MRAFF process involves extruding the MR fluid through the workpiece under a magnetic field, where abrasives held by iron chains rub peaks and shear material in a controllable way set by the field strength.
Chemical machining
This presentation gives an information about introduction to Chemical machining covering the syllabus of Non Traditional Machining.
Diamond turn machining
Diamond Turn Machining
Diamond turning is turning using a cutting tool with a diamond tip. It is a process of mechanical machining of precision elements using lathes or derivative machine tools equipped with natural or synthetic diamond-tipped tool bits.
Introduction
Components and machine structure
Different types of equipment
Tooling specifications
Tolerance and aspect ratios
Working principle
Control systems and power requirement
Process parameters
Material to be machined
MRR and surface finish
Advantages and disadvantages
Applications
Advancement in DTM
Machine characteristics
Machine tool requirement
Bar graphs and tables
Conclusion
References
Animation video
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This document provides information about an Unconventional Machining Processes course. It includes the course code, regulation, instructor details, course outcomes, modules, and learning outcomes. Specifically, it outlines Module I which provides an introduction to unconventional machining processes, including ultrasonic machining. It discusses the history, principles, setup, mechanisms, materials used, applications, and limitations of ultrasonic machining.
Ultrasonic Machining
1) Ultrasonic machining uses high frequency vibrations and abrasive particles to machine hard and brittle materials through microchipping.
2) Piezoelectric and magnetostrictive transducers are used to generate the ultrasonic vibrations, while abrasive slurry carries away debris from the cutting area.
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This document provides an overview of ultrasonic machining including its history, key parts, working principle, advantages, disadvantages, and applications. Ultrasonic machining uses ultrasonic vibrations and an abrasive slurry to machine hard, brittle materials without causing damage from heat. It has advantages like being able to machine non-conductive materials and producing burr-free parts. However, it has low material removal rates and requires tooling that wears from the abrasive particles. Ultrasonic machining is used for applications like machining ceramics, cutting industrial diamonds, and drilling dental cavities without pain.
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Ultrasonic machining adalah alat non konvensional dengan menggunakan metode frekuensi suara ultrasonic
Chapter 3 usm
Ultrasonic machining is a non-traditional machining process that uses abrasive particles in a slurry to machine hard and brittle materials. In the process, a tool oscillates at ultrasonic frequencies (19-25 kHz) with an amplitude of 15-50 microns over the workpiece while being flooded with an abrasive slurry. Material is removed through crack initiation and brittle fracture as the abrasive particles indent the workpiece material. Ultrasonic machining can machine materials that are too hard for conventional machining or that cannot be processed through EDM or ECM due to being non-conductive. Key components of ultrasonic machining equipment include a generator, transducer, tool
A Review On Ultrasonic Machining.Pdf
The document discusses ultrasonic machining (USM), a non-traditional machining process used to machine hard and brittle materials like ceramics and quartz. USM works by vibrating an abrasive tool at ultrasonic frequencies (over 20 kHz), which causes abrasive particles in a slurry to impact and micro-chip the workpiece surface, removing material. The document provides an overview of USM, reviewing how it works, common operating parameters, and models that have been proposed to describe the material removal mechanisms in USM.
ucml.ppt
The document discusses non-traditional machining processes. It defines these processes as those that remove material using techniques involving mechanical, thermal, electrical or chemical energy rather than traditional sharp cutting tools. The document outlines the key characteristics of non-traditional machining, provides examples of different types of processes classified by energy type used, and discusses specific processes like abrasive jet machining and ultrasonic machining in more detail.
Ultrasonic Machining.pptx
This document discusses ultrasonic machining (USM), an unconventional machining process used to machine hard and brittle materials. USM uses a vibrating tool and abrasive slurry to erode material from the workpiece. It can machine materials harder than 40 HRC like ceramics and carbides that cannot be conventionally machined. USM produces precision features with a smooth surface finish without causing heat damage. While it has a high initial cost and low material removal rate, USM is useful for machining difficult materials like glass, ceramics, and carbides that are used in applications like wire drawing dies, dental drills, and cutting diamonds.
RUM ( Rotatory Ultrasonic Maching)
This document provides an overview of rotary ultrasonic machining (RUM), also known as micro-ultrasonic machining (MUSM). It defines micromachining and RUM/MUSM, explaining that RUM allows machining features down to 100 micrometers. The document outlines the RUM process, including using a rotating tool with diamond abrasives that machines materials via ultrasonic impacts and grinding. It discusses RUM equipment, process parameters like tool type and vibration conditions, and applications for machining hard materials like titanium alloys, silicon carbide, and dental ceramics.
Ultrasonic machining
Ultrasonic machining is a nontraditional machining process where a tool oscillating at high frequency contacts a workpiece with an abrasive slurry between them. The abrasive particles driven by the tool remove small pieces of the workpiece by fracturing it. Key aspects of ultrasonic machining include using a transducer to convert electrical energy to mechanical vibrations at 15-30 kHz, concentrating this vibration through an acoustic horn onto the tool, and supplying an abrasive slurry mixture to act as a medium between the tool and workpiece.
Usm g.venkatesh
Ultrasonic machining (USM) involves removing material from a workpiece using high-frequency vibrations and an abrasive slurry. Key components of USM include a generator, transducer, horn, tool, abrasive slurry, and workpiece. The main material removal mechanisms are mechanical abrasion, impact, erosion, and chemical effects. USM can machine hard and brittle materials like ceramics and has advantages like avoiding thermal/mechanical damage but has limitations like lower material removal rates compared to other processes. Process parameters that influence the material removal rate include amplitude, frequency, abrasive size, and slurry properties.
UNIT-2-1.pptx
Ultrasonic machining (USM) is a non-traditional machining process that uses a vibrating tool and abrasive slurry to machine hard and brittle materials. In USM, the tool vibrates at ultrasonic frequencies (over 20 kHz) which causes abrasive particles in the slurry to remove small amounts of material from the workpiece. Key factors that influence the material removal rate include the amplitude of vibration, abrasive particle size, tool material, and workpiece hardness. USM can achieve high accuracies between 7-25 μm and is well-suited for machining intricate shapes in hard materials like carbides, ceramics, and glass.
NON CONVENTIONAL MACHINING PRESENTATION
This document provides an overview of non-conventional machining processes including electron beam machining (EBM), laser beam machining (LBM), and ultrasonic machining (USM). EBM uses a focused beam of high velocity electrons to melt and evaporate material. LBM uses a high power laser beam capable of high power density to melt and evaporate material. USM uses a tool that vibrates at ultrasonic frequencies in an abrasive slurry to erode material away. Non-conventional machining processes allow machining of materials that are difficult to machine with conventional methods and provide benefits like higher accuracy, less heat impact, and ability to machine complex shapes.
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Ultrasonic Micro-machining
- 1. Submitted by, • Amartya Roy(1602218)
- 2. History of USM • Pierre Curie in around 1880 found that asymmetrical crystals such as quartz and Rochelle salt generate an electric charge when mechanical pressure is applied • Mechanical vibrations are obtained by applying electrical oscillations to same crystals • First application of USM was sonar(an acronym for sound navigation ranging). It's used by the U.S. Navy during WW-II. • Nowadays its applications includes medical imaginng, testing cracks etc.
- 3. Principle of USM Working principle of Ultrasonic Machining or Ultrasonic Impact Grinding is described with the help of a schematic diagram. The shaped tool under the actions of mechanical vibration causes the abrasive particles dipped in slurry to be hammered on the stationary workpiece.
- 4. What is Micro USM? • Micro products and components offer unique advantages. They occupy less space,consume less energy and material. • Micro USM is such a complimentary process capable of micromachining. • In Micro USM the same work is been done in micro level
- 5. Process Paramet of Micro USM • MRR • Tool Material • Tool wear rate • Abrasive materials and abrasive slurry • Surface finish • Work material
- 6. Relationship of MRR with other parameters
- 7. • Advantages of Micro USM 1. For machining of hard & brittle materials 2. For machining in micro level 3. Complex and small ahapes can be cut 4. For drilling of non-circular holes in material like glass • Disadvantages of Micro USM 1. Cann't machine conductive materials 2. Not suitable for ductile materials 3. High tool wear 4. Setup cost is high
- 8. Work examples of Micro USM
- 9. Spectrum of Sound Frequency range (Hz) Description Example 0-20 Infrasound Earth quake 20-20,000 Audible Sound Speech, music >20,000 Ultrasonic Bat, quartz crystal
- 10. Applications of Micro USM 1. Drilling
- 11. 2. Grinding
- 12. 3. Profiling
- 13. 4. Coining
- 14. Safety considerations • The workers must be wearing eye goggles to prevent the abrasive particles or the microchips from getting into his eyes • They should wear appron while working
- 15. Bibliography • Excerpt from S.K Mohapatra Sir's notes • Wikipedia • Google • SlideShare