Ultrasonic Machining / Definition, parts, working, advantages, disadvantages of Ultrasonic Machining

Introduction:

Ultrasonic machining is also a mechanical energy based non-conventional machining process that is used to machine brittle and hard materials.  

In ultrasonic machining, ultrasonic waves are converted into mechanical vibrations, through the magnetostrictive effect.

The ultrasonic machine generates a  frequency of 20000 to 30000 Hz. 

This process is used for cutting metal in many industries because of its low cost, no heat generated, and efficient machining.

See in the figure the ultrasonic machining process and their working procedure described below in detail.

types of unconventional machining process

Ultrasonic Machining

Working Procedure of Ultrasonic Machining:

1. First of all the low-frequency electric current is sent from the power supply (electric supply). 
2. This low frequency current is converted into high frequency current through some electrical equipment.  
3. This high frequency current passes through the transducer. The transducer converts this high frequency electric signal to high frequency mechanical vibration.  
4. This mechanical vibration passes through the booster.  
5. The booster amplifies this high-frequency vibration and sends it to the horn.
6. Horn, also known as a tool holder, transferred this amplified vibration to the tool. Where the tool vibrates at an ultrasonic frequency. 
7. An abrasive gun is used to supply an abrasive slurry (eg, aluminum oxide, silicon carbide, boron carbide, diamond dust, etc.) and the mixture of abrasive slurry and water is sent between the tool and the workpiece. 
8. As the instrument vibrates, the abrasive slurry also starts vibrating at this high frequency. 
9. This abrasive slurry attacks the workpiece and gives it a metallic appearance.

Application of Ultrasonic Machining:

1. It is used to produce fine holes. 
2. It is the best suited machine for hard and brittle materials. 
3. With the help of this, a cavity or hole is easily made in the dies.

Advantages of Ultrasonic Machining:

1. The workpiece is free from any stress after machining.  
2. Extremely hard and brittle materials can be easily removed.
3. Excellent accuracy and surface finishing are achieved. 
4. Operational cost is very low. 
5. This process is environmentally friendly as it takes place without any chemical reactions and heating. 
6. goog_1511328771It is suitable for both conducting and non-conducting materials.

Disadvantages of Ultrasonic Machining :

1. In this, the metal removal rate is low and can not be used for large machining operations.
2. The initial cost and initial cost of the equipment are very high. 
3. The power consumption is quite high. 
4. The slurry may need to be changed frequently.
5. goog_1511328773Equipment life is short.

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