Ultrasonic machining is a non-traditional machining process that removes material from a part through high-frequency vibrations of a tool against the material surface in the presence of abrasive particles. It involves vibrating a tool at ultrasonic frequencies to erode unwanted material with abrasives. This allows for machining very hard and brittle materials. The machining time depends on factors like vibration frequency, material properties, and abrasive grain size. Applications include machining hard materials like ceramics and glass as well as dental and turbine blade work.

1. B Y B . C H A N A K Y A
ULTRASONIC MACHINe

2. ABSTRACT
ULTRASONIC MACHING 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

3. Ultrasonic machine parts

4. Working Principal

5. Machining Time
• Machining time of ultrasonic machine or ultrasonic
machine depends on the frequency of the vibration,
material properties and grain size.
• The amplitude of the vibration may vary from 5 to
75µm and frequency may vary from 19~25kHz.
• Ample static force is also required to hold the job
against the machining tool
• A continues flow of abrasive suspension is also
mandatory

6. Schematic Presentation of USM Process

7. Applications
 Machining of extremely hard and brittle materials
can be performed with ease
 This method is mostly preferred in dentistry work for
fine drilling holes of required shaped in teeth
 It is used to perform coining operations for materials
such as glass, ceramics etc.
 It is also been employed for multistep processing for
fabricating silicon nitride turbine blades.

8. Advantages
 There is no generation of heat in this process.
 There is no change in physical properties of job
during machining.
 Machining of hard and brittle material can be
performed very easily.
 There is no residual stress in the machined work
piece.

9. Disadvantages
 The metal removal rate from the work piece is very
low.
 Initial machining and tooling costs are high.
 Power consumption is high.
 Limited sized cavities are produced by this
machining process.

10. Summary
 Mechanics of material removal : Brittle fracture
caused by impact of abrasive grains due to vibrating
at high frequency
 Medium : Slurry
 Abrasives :Boron carbide , silicon carbide ,
diamond dust.
 Material applications : metals and alloys,
semi conductors , nonmetals.
 Limitations: very low mrr, tool wear , small cavities.

11. References
 http://www.slideshare.net/shorokhaibam/maulana
 http://mechanicalinventions.blogspot.in/2015/09/u
ltrasonic-machining-usm-working.html
 https://www.google.co.in/search?q=ultrasonic+mac
hining+process+pdf&biw=1366&bih=705&espv=2&s
ource=lnms&tbm=isch&sa=X&ved=0ahUKEwjXuY
Gj89HLAhVFj44KHYedDn4Q_AUICCgC#tbm=isch
&q=schematic+diagram+ofultrasonic+machine+&i
mgrc=T6Jq0LCFTsHaNM%3A
 Spectrum