Principle of ultrasonic machining in the machining process, the tool, at some point, impacts on the largest grits, which are forced into the tool and workpiece. Micro ultrasonic machining musm is a method derived from conventional ultrasonic machining, in which a tool and free abrasives are used. Micro ultrasonic machining micro usm, is one of the efficient material removal processes especially suitable for the micromachining of hard and brittle materials. Advanced nontraditional machining processes 303 work. As the tool continues to move downwards, the force acting on these grits increases rapidly, therefore some. Slurry of abrasive and water vibration frequency f 19 25 khz amplitude, a 10 50. Given this, nontraditional machining is widely utilized in responding to modern industrial problems. Apr 15, 20 ultrasonic machining introduction ultrasonic machining is a nontraditionalmechanical means of uniform stock materialremoval processit is applicable to both conductive andnonconductive materials. Mar 19, 2020 ultrasonic machining is a method of grinding that uses an abrasive liquid rather than direct tool contact. Abrasive waterjet cutting of microelectronic components mohamed hashish flow international corporation kent, wa abstract a new process for cutting and singulating chips has been commercially introduced. That machining makes the plane compelling in ways that have led other countries to take up some of the cost. Introduction in the vast and complex field of electrotechnologies, electrochemical machining technique ecm represents a relatively new and important method of.
Lathe tools may benefit from deliberatelyinduced vibrations to prevent chatter which compromises the surface finish of the finished component. Usm is grouped under the mechanical group ntm processes. History the roots of ultrasonic technology can be traced back to research on the piezoelectric effect conducted by pierre curie around 1880. Ultra sonic machining has a vast application in modern world. Oct 22, 2008 lecture series on manufacturing processes ii by prof.
Advanced casting processes metal mould casting continuous casting squeeze casting vacuum mould casting evaporative pattern casting ceramic shell casting 6 3. Usm is mechanical material removal process or an abrasive process used to erode holes or cavities on hard or brittle workpiece by using shaped tools, high frequency mechanical motion and an abrasive slurry. Graphite can be machined with standard machine shop equipment. Non traditional machining processes, also called advanced manufacturing processes, are employed where traditional machining processes are not feasible, satisfactory or economical due to special reasons as. Combining ultrasonic and conventional machining operations. Complete machining of components with rotationalsymmetric properties incl. The method of making contact of metal with the enchant is masking. Ultrasonic machining, or strictly speaking the ultrasonic vibration machining, 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. Advanced welding processes details of electron beam welding ebw laser beam welding lbw ultrasonic welding usw 6 4. Particularly suited for very hard andorbrittle materials such asgraphite, glass, carbide, and. An experimental study on ultrasonic machining of pure titanium using designed experiments in the present research work, the effect of several process parameters on the machining characteristics of pure titanium astm gradei has been reported. Introduction, history of machining, traditional machining processes, nontraditional machining processes, hybrid machining processes. Extremely hard and brittle materials are difficult to machine by traditional machining processes such as turning, drilling, shaping and milling.
Part 2 deals with thermal machining processes for example, electric discharge machining, laser beam machining, electron beam machining, etc. In this study, a novel chemicalassisted ultrasonic machining cusm method is introduced to overcome former disadvantages. Download as pptx, pdf, txt or read online from scribd. Electrochemical machining works on the principles of electrolysis. Here is a look at a highvalue, highly engineered machining process for the joint strike fighter aircraft. Ultrasonic machining is a mechanical material removal process that uses formed tools, vibration of high frequency and abrasive slurry mix. Nontraditional machining processes flashcards quizlet. Ultrasonic vibrationassisted uva machining is a process which makes use of a microscale high frequency vibration applied to a cutting tool to improve the material removal effectiveness. Unconventional machining process anna university question paper. Ultrasonic machining is ultrasonic machining processes, as being developed and applied at ewi, consist of the. Different graphical representation and the metal removal rate of the process.
This paper presents a new method in machining of materials using cavitation process. Pdf ultrasonic machining effects on the surface finish and. To get the chemical effect, a low concentration of hydrofluoric acid was added to the abrasive slurry. Most grinding processes involve a work tool making direct contact with a work piece in order to gouge material away.
Ultrasonic technology poised for advance into general machining. Pdf ultrasonic machining effects on the surface finish. Ultrasonic machining offers an effective alternative for ultra precision machining of hard and brittle materials due to its unique characteristics. The ultrasonic machining center is also a fully capable conventional machining center. The machined surface produced by ultrasonic machining is found to be free from any surface defects heat affected zone, cracks, recast layer, etc. The shape and the dimensions of the workpiece depend on those of the tool. Electrochemical machining, ultrasonic processing, hybrid machining processes, depassivation 1. Rather than discuss a single set of experimental work in detail, this paper discusses some of the issues that have been encountered when applying the technique of ultrasonic assisted machining. The process is more effective on materials that have hardness more than rc 40, but it is used on almost all including metallic and nonmetallic materials such as glasses, ceramics, and composites. The tool that is vibrated at ultrasonic frequency drives the abrasive to create a brittle breakage on the workpiece surface. Usm offers a solution to the expanding need for machining. Ultrasonics have been used in several ways for machining metals.
Optimization of the machining parameters for ultrasonic. Ultrasonic machining from the technology data exchange linked to trusted tde listed vendors. The main working principle of chemical machining is chemical etching. Aug 07, 2017 this feature is not available right now. Rotary ultrasonic machining of hardtomachine materials by nikhil churi b. Ultrasonic technology poised for advance into general.
Ultrasonic horn design for ultrasonic machining technologies. Ultrasonic machining national institute of technology. Water jet and abrasive water jet machining youtube. Thanks for using our companys products, in order to fully make. Ultrasonic machining is a contemporary manufacturing method usually employed for processing materials with higher hardnessbrittleness such as quartz, semiconductor materials, ceramics etc. Grinding ultrasonic machining chemical machining electrochemical machining electricaldischarge machining highenergybeam. This paper did a comprehensive analysis on ultrasonic machining mechanism in theory. The experiment compared this ultrasonic machining process with the common machining process in. Unconventional machining process nov,dec2014, may 2014 r2008,unconventional machining process may 2014 r2008,2010,unconventional machining process nov,dec20,unconventional machining process dec2012,unconventional machining process ap,may2008,unconventional machining process may2009,unconventional machining process nov,dec2009,unconventional machining process. Keber make some types standard robot ultrasonic welding machineone mechanical arm or two mechanical arms per order quantity requirement, mechanical arm brand normally we choose abb, but can be chosen other brand per customers requirement.
Nov 29, 2016 ultrasonic machining involves imparting ultrasonic vibrations of frequency 20 khz to a tool to effect material removal. It is important to make provisions to control the dust created by the machining operation. The machining characteristics that are being investigated are tool wear rate and the quality of the. Sharma, department of mechanical engineering, iit roorkee. During the warranty period, the manufacturer will, at its option, as the exclusive remedy. The basic usm process involves a tool made of a ductile and tough material vibrating with a low amplitude and very high frequency and a continuous flow of an abrasive slurry in the small gap between the tool and the work piece.
Ultrasonic enhancement of an electrochemical machining. Ultrasonic machining is a mechanical type nontraditional machining process. As the tool continues to move downwards, the force acting on these grits increases rapidly, therefore some of the grits may be fractured. An experimental study on ultrasonic machining of an. Electron beam machining ebm laser beam machining lbm processes 2. Introduction the technology of high power ultrasonics, already extensively applied at ewi in the fields of welding, solderingbrazing and additive manufacturing, is now being extended to the field of ultrasonic machining.
Non traditional machining jagadeesha t, assistant professor, med, national institute of technology, calicut equipment. Ultrasonic machining involves imparting ultrasonic vibrations of frequency 20 khz to a tool to effect material removal. Paul,department of mechanical engineering, iit kharagpur. Unconventional machining process nov,dec2014, may 2014 r2008,unconventional machining process may 2014 r2008,2010,unconventional machining process nov,dec20,unconventional machining process dec2012,unconventional machining process ap,may2008,unconventional machining process may2009,unconventional machining process nov,dec2009,unconventional machining process nov,dec2010. The part of the workpiece whose material is to be removed, is brought into the contact of chemical called enchant. This is to certify that the thesis entitled, optimization of the machining parameters for ultrasonic vibration assisted turning of hard material submitted by mr. A new nontraditional machining method using cavitation. Ultrasonic drills, used on very hard ceramics, work by grinding or eroding material away a liquid slurry around. Parametric optimization of ptfe using ultrasonic machining. The process is more effective on materials that have hardness more than rc 40, but it is used on almost all including metallic and. In ultrasonic machining, a liquid filled with abrasive material flows through over the work piece, and the work tool vibrates against the abrasives. Particularly suited for very hard andorbrittle materials such asgraphite, glass, carbide, and ceramics. Ultrasonic machining centers can perform both conventional and ultrasonic machining operations.
Ultrasonic machining, water jet machining, abrasive water jet machining. A new nontraditional machining method using cavitation process. It also includes micronanofinishing processes viz, abrasive flow finishing, magnetic abrasive finishing, etc. Research on the machining principle and experinment of.
Ultrasonic machining is a method of grinding that uses an abrasive liquid rather than direct tool contact. By using this method, metal should be removed so easily and also with a short time. Wallace says the typical use of this machine would be conventional metalcutting most of the time, with the ultrasonic head loaded into the spindle for the parts and operations benefitting most from this capability. Lecture series on manufacturing processes ii by prof. Unlike other nontraditional processes such as laser beam, and electrical discharge machining, etc. Although the impact pressure at the machining points is high owing to the ultrasonic oscillation of a high frequency and the small sizes of grains, the machining load is small enough to prevent the generation of large cracks in brittle materials. Applied and computationalmechanics4 2010 7988 ultrasonic horn design for ultrasonic machining technologies m. Ultrasonic machining introduction ultrasonic machining is a nontraditionalmechanical means of uniform stock materialremoval processit is applicable to both conductive andnonconductive materials. What are the major nontraditional machining processes. Experimental study of micro ultrasonic machining process.
External and internal cylindrical grinding of advanced materials for accurate geometries and optimum surface qualities. Ultrasonic machining is of particular interest for the cutting of nonconductive, brittle workpiece materials such as engineering ceramics. Miyan ram 1709653 1 introduction ultrasonic machining usm is the removal of hard and brittle materials using an axially oscillating tool at ultrasonic frequencies 1820 khz during that oscillation, the abrasive slurry of b4c or sic is continuously fed into the machining zone between a soft tool brass or steel and the workpiece. Ultrasonic machining is a nontraditional process, in which abrasives contained in a slurry are driven against the work by a tool oscillating at low amplitude 25100 microns and high frequency 1530 khz. In micro usm workpiece which is placed on the workpiece table vibrates at ultrasonic frequency 40 khz. Ultrasonic machining is a nontraditional machining process. Its principle is to make the toolworkpiece interaction a microscopically nonmonotonic process to facilitate chip separation and to reduce machining forces. This process is based on cutting contoured lines with finebeam 0. Ultrasonic machining is a nonconventional machining process. The metal is removed by the chemical attack of enchant.
Ultrasonic machining ultrasonics have been used in several ways for machining metals. Ultrasonic technology machines hard, brittle materials accurately and easily. Unconventional machining process anna university question. Jun 22, 2010 introduction the technology of high power ultrasonics, already extensively applied at ewi in the fields of welding, solderingbrazing and additive manufacturing, is now being extended to the field of ultrasonic machining. Ultrasonic cutting of cheese and apples effect on quality attributes during storage by gulcin yildiz thesis submitted in partial fulfillment of the requirements for the degree of master of science in food science and human nutrition with a concentration in food science in the graduate college of the. However, despite the above benefits, ultrasonic machining has a low material removal rate and gives low surface quality. Ultrasonic enhancement of an electrochemical machining process. Dec 01, 2011 ultrasonic machining is an easytouse technology that allows a mold manufacturer to machine very hard or brittle materials with flexibility and accuracy.
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