Ultrasonic machining uses high frequency vibrations and an abrasive slurry to erode small holes and cavities in hard materials. It works by applying pressure between an oscillating tool and the workpiece in the presence of abrasive particles. Key components include a power supply, transducer, tool holder and abrasive slurry. The slurry typically contains boron carbide or silicon carbide abrasives in a liquid like water or oil. Ultrasonic machining can precisely machine brittle materials without causing thermal or chemical damage thanks to its non-thermal nature.

1. Ultrasonic
machining(USM)
Martin
Aeronautical

2. Over view :
Principle
Components
Specifications
Parameters
Advantages
Dis advantages
Applications

3. Principle:
• Ultrasonic machining is a non-traditional machining
process means of uniform stock material removal
which is used to erode material in form of fine holes
and cavities in hard or brittle workpiece.
• it uses formed tools,vibrations of high frequency
and a suitable abrasive material to remove the
material
• Frequency>20,000hz

4. System
components
Power supply
Transducer
Tool holder
Tool
Abrasive slurry

5. Abrasive slurry:
Abrasive material:
• boron carbide
• Silicon carbide
• Corundum
• Diamond
• Boron silicon carbide
Liquid:
• Water
• Benzene
• Glycerol
• Oils
• High viscosity
decreases MMR

6. Specifications:
• The tool should be made up of low carbon steel or
stainless steel for good performance
• Tools are usually 25 mm long;its size is equal to hole
size minus twice the size of abrasives.
• Mass of the tool should be minimum possible so that
it does not absorb the ultrasonic energy.
• Surface finish of tool should be notified as it
replicates in the workpiece.

7. Process parameters
• Amplitute of vibration(a)-15-50 micro-meter
• Frequency of vibration(f)-19-25khz
• Feed force(F)
• Feed pressure(p)
• Abrasive size-15-150micro-meter
• Contact area of tool-A
• Volume concentration of abrasive in slurry-C.

9. Advantage
• Machining any materials regardless their conductivity.
• It is used for machining of semi conductor such as silicon
, germanium ,.etc.
• USM is suitable to precise machining of brittle material
• USM does not produce electric,thermal,chemical
abnormal surface.
• Can drill circular or non-circular holes in very hard
material.
• Less stress because of its non-thermal characteristics

10. Disadvantages
• USM has low material rate.(3-15mm/min)
• Tool wears fast in USM.
• machining area and depth is restraint in USM

11. Applications:
• It is mainly used for
• Drilling
• Grinding
• Profiling
• Coining
• Piercing of dies
• Welding operations on all materials which can be treated
suitably by abrasive.
• Used for machining hard and brittle metallic
alloys,semiconductors,glass,ceramics,carbides etc.
• Used for machining round,square,irregular shaped holes and
surface impressions.

12. Educational videos:
https://youtu.be/5w6szZtOg5w
https://youtu.be/jj9s5NhzfnY