Ultrasonic machining uses a vibrating tool at ultrasonic frequencies to machine hard, brittle materials with little heat generation. It works by using an abrasive slurry between the tool and workpiece. The process allows machining of non-conductive materials that cannot be cut via other methods. It produces burr-free surfaces but has low material removal rates and high tool wear. Applications include machining ceramics, semiconductors, glass, and other hard materials, as well as drilling small, deep holes without damaging surrounding structures.

1. Ultrasonic Machining
Presented by-
P. Deepak Kumar

2. Contents
Introduction
Ultrasonic Machine Parts
Working
Advantages
Disadvantages
Applications

3. Introduction
Also Known as Ultrasonic Impact Grinding.
Vibrating tool at ultrasonic frequency.
Use of abrasive slurry.
Very little heat generated.

4. Ultrasonic Machine Parts

5. Working

7. Advantages
 It can be used machine hard, brittle, fragile and non
conductive material.
 No heat is generated in work, therefore no
significant changes in physical structure of work
material.

8.  Non-metal (because of the poor electrical
conductivity) that cannot be machined by
EDM and ECM can very well be machined
by USM.
 It is burr less and distortion less processes.
 It can be adopted in conjunction with other
new technologies like EDM,ECG,ECM.

9. Disadvantages
 Low Metal removal rate.
 It is difficult to drill deep holes, as slurry
movement is restricted.

10. Tool wear rate is high due to abrasive particles.
Tools made from brass, tungsten carbide, MS or
tool steel will wear from the action of abrasive grit
with a ratio that ranges from 1:1 to 200:1.
USM can be used only when the hardness of work
is more than 45 HRC.

11. Applications
 Machining of cavities in electrically non-
conductive ceramics
 Used to machine fragile components in which
otherwise the scrap rate is high
 Used for multistep processing for fabricating
silicon nitride (Si3N4) turbine blades

12.  Used for machining hard, brittle metallic alloys,
semiconductors, glass, ceramics, carbides etc.
 Used for machining round, square, irregular
shaped holes and surface impressions.
 Used in machining of dies for wire drawing,
punching and blanking operations

13.  USM has been used for piercing of dies and for
parting off and blanking operations.
 USM enables a dentist to drill a hole of any shape
on teeth without any pain.
 Ferrites and steel parts , precision mineral stones
can be machined using USM

14. USM can be used to cut industrial diamonds
USM is used for grinding Quartz, Glass,
ceramics
Cutting holes with curved or spiral centre lines
and cutting threads in glass and mineral or
metallo-ceramics

15. USM can perform machining operations like
drilling, grinding and milling operations on all
materials which can be treated suitably with
abrasives.
Large number of holes of small diameter. 930
holes with 0.32mm has been reported
(Benedict, 1973) using hypodermic needles.

16. Thank you