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Ultrasonic Machining Process
- 4. SUITABLE
- 5. PRINCIPLE
- 7. . Ultrasonic Generator Used to convert the current from low frequency to high frequency
- 9. . Transducer Used to convert Electrical energy into Mechanical Vibrations
- 10. . Tool Holder Made up of Titanium alloy , Monel , Aluminium, Stainless steel
- 11. . Tool Material Low Carbon Material and Stainless steel The tool is brazed, soldered or Fastened mechanically to the transducer through a tool holder
- 12. Working of USM
- 13. Transducer convert the high frequency electrical energy into Mechanical Vibrations Oscillator convert the Low frequency electrical energy into high frequency electrical energy 20 – 30 HZ Vibrations are transferred to tool material Abrasive Slurry Passed Between the vibrating tool and work piece The refrigeration system used to cool the abrasive slurry to 5 – 6 Degree celcius
- 14. COMPARISON
- 15. TRANSDUCER
- 17. MAGNETOSTRICTIVE TRANSDUCER . Change in length is independent of the direction of the magnetic field But depend only on the magnitude of the field and Nature of the material
- 19. MAGNETOSTRICTIVE TRANSDUCER LT battery used to heat the filament So electrons are produced Those electrons are accelerated by HT Battery So AC current Produced in the circuit
- 20. So Rod start to vibrate due to magnetostric tive effect This vibrations rod create Ultrasonic Waves , which sent out MAGNETOSTRICTIVE TRANSDUCER
- 21. MAGNETOSTRICTIVE TRANSDUCER The Longitudinal Extension and contraction of the Rod AB produce an EMF in the coil L2
- 22. Resonance Frequency of the oscillatory circuit Frequency of Vibrating Rod = Resonance will occur when At resonance , the rod vibrates vigorously and ultrasonic waves are produced at high frequencies
- 25. PIEZOELECTRIC TRANSDUCER Its more efficient than magnetostrictive transducer The modern USM are of this type.
- 27. Definition - Piezoelectric • Piezoelectric transducers are a type of electro acoustic transducer that convert the electrical charges produced by some forms of solid materials into energy. • The word "piezoelectric" literally means electricity caused by pressure.
- 28. Circuit
- 29. Arrangement of the circuit
- 30. Working LT battery used to heat the filament So electrons are produced Those electrons are accelerated by HT Battery So AC current Produced in the circuit This AC current Passes through L1 and L2 and its transferred to Secondary circuit This AC current passed to the plates A and B and it make the Crystal to vibrate due to the principle of inverse piezoelectric effect. The vibrations of crystal creates Ultrasonic waves
- 31. Resonance
- 32. Advantages – Piezoelectric transducer Disadvantages – Piezoelectric transducer 1. Piezoelectric quartz is high cost 2. Cutting and shaping of crystal is very complex.
- 33. MRR MRR Per unit time
- 34. Wear Ratio
- 35. Factors considered for MRR in USM
- 36. Grain size of Abrasives
- 37. Abrasive material It Depend on 1.The type of material to be machined 2. Requirement of Surface finish For Machining - Tungsten Carbide - Die Steel Boron Carbide Silicon Carbide Abrasives For Machining - Glass - Ceramics Aluminium oxide
- 38. Concentration of Slurry Abrasive Slurry = Abrasive Particles + Water
- 39. Amplitude of Vibration MRR increase with the increase of Amplitude of Vibration
- 40. Frequency MRR increases with the increase of Ultrasonic wave Frequency
- 42. Tool Material Lengthy tool causes overstresses So tool should be short and rigid Process Parameters
- 43. Process Parameters Wear Ratio 1.5 : 1 For Tungsten Carbide Work Pieces 100 : 1 For Glass Work Pieces 50 : 1 For Quartz Work Pieces 75 : 1 For Ceramics 1 : 1 For Hardened tool steel Work Pieces
- 44. Abrasive Material and Cutting Power Process Parameters
- 47. Applications