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    Assignment#3 Group #2: Manufacturing Process Ultrasonic Machining

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    The Noob
    The document describes ultrasonic machining, a non-traditional machining process. It involves vibrating a tool at high frequency against a workpiece in an abrasive slurry to remove material. Key components are the transducer, sonotrode, abrasive slurry, and power supply. Ultrasonic machining can drill holes in hard materials like carbides and ceramics. It produces less heat and finer finishes than conventional machining.

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    Assignment#3 Group #2: Manufacturing Process Ultrasonic Machining

    Uploaded by

    The Noob
    88 views16 pages
    The document describes ultrasonic machining, a non-traditional machining process. It involves vibrating a tool at high frequency against a workpiece in an abrasive slurry to remove material. Key components are the transducer, sonotrode, abrasive slurry, and power supply. Ultrasonic machining can drill holes in hard materials like carbides and ceramics. It produces less heat and finer finishes than conventional machining.

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    Materials Engineering. manufacturing process, ultrasonic machining

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    The document describes ultrasonic machining, a non-traditional machining process. It involves vibrating a tool at high frequency against a workpiece in an abrasive slurry to remove material. Key components are the transducer, sonotrode, abrasive slurry, and power supply. Ultrasonic machining can drill holes in hard materials like carbides and ceramics. It produces less heat and finer finishes than conventional machining.

    Copyright:

    © All Rights Reserved
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    Download as pptx, pdf, or txt
    88 views16 pages

    Assignment#3 Group #2: Manufacturing Process Ultrasonic Machining

    Uploaded by

    The Noob
    The document describes ultrasonic machining, a non-traditional machining process. It involves vibrating a tool at high frequency against a workpiece in an abrasive slurry to remove material. Key components are the transducer, sonotrode, abrasive slurry, and power supply. Ultrasonic machining can drill holes in hard materials like carbides and ceramics. It produces less heat and finer finishes than conventional machining.

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    © All Rights Reserved
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    Download as pptx, pdf, or txt
    of 16

    ASSIGNMENT#3

    GROUP #2
    MANUFACTURING PROCESS
    ULTRASONIC MACHINING
    Group Member:
    Aris Maknojia (me181037)
    Hussain Hatim (me181047)
    Haseeb Durrani (me181048)
    Class:BE-ME-5B
    CONTENT
     Introduction
     Difference between conventional and non-conventional Machining
     Ultrasonic Machining
     Need for Ultrasonic Machining
     Schematic diagram of Ultrasonic Machining
     Main Parts of Ultrasonic Machining
     Sub-parts of Ultrasonic Machining
     Working Principle of Ultrasonic Machining
     Process Parameters
     Applications Of Ultrasonic Machining
     Advantages of Ultrasonic Machining
     Disadvantages of Ultrasonic Machining
    INTRODUCTION
     Material removal is a shaping process in which undesired excess material
    is removed from the starting work piece so the remaining part becomes
    closer to the desired shape.
     In other words we can define material removal process as the
    manufacturing process in which we obtain a final product by removing
    excess material from the work piece.
     The best example of a machining process is generating a cylindrical
    surface from metal stock with the help of the lathe.
     Material removal process can be divided into two groups:
    1. Conventional Machining Process
    2. Unconventional Machining Process
    DIFFERENCE B/W CONVENTIONAL AND
    NONCONVENTIONAL MACHINING
    Conventional Machining Non-conventional Machining
    Direct contact of tool and work piece. Doesn’t require direct contact of tool and work piece.

    Cutting tool is always harder than Tool may not be harder and it may not be physical
    work piece. presence.

    Tool life is less due to high wear. Tool life is more.


    Conventional machining process has lower accuracy non-conventional machining has higher accuracy
    and surface finish and surface finish.

    Examples: turning, boring, milling, shaping etc. Examples: Ultrasonic machining, Abrasive jet
    machining etc.
    ULTRASONIC MACHINING
     Ultrasonic machining is a subtractive manufacturing process or we
    can say mechanical removal 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.
     It is a non-conventional machining process in which harder
    material is machined. It is particularly suited for very hard (brittle
    Material) such as graphite, glass, carbide and ceramics.
     It is used to erode material in the form of fine holes and cavities in
    hard (brittle) work piece.
    NEED FOR ULTRASONIC MACHINING
    Ultrasonic machining are mainly use:
    To achieve high accuracy and surface finish of high strength
    material.
    To produce complex shapes.
    For machining of composites.
    For producing deep hole with small hole diameter.
    For high rate material removing.
    For engraving.
    SCHEMATIC DIAGRAM OF ULTRASONIC
    MACHINING
    Main Parts of Ultrasonic Machining

    The ultrasonic machining machine consists of two main


    parts transducer and sonotrode (also called as horn),
    connected to an Electronic control unit with cables.
    1. Transducer: The transducer mainly consists of a cylinder
    which is made up of piezoelectric ceramic. It converts electrical
    energy into mechanical vibration. Transducer then vibrates
    sonotrode at low amplitude and high frequency.

    2. Sonotrode: It is made of low carbon steel. One end of it is


    connected with the transducer and other end contains tool. The
    sonotrode vibrates at low amplitude and high frequency and
    removes material from the workpiece by abrasion where it
    contacts it.
    SUB-PARTS OF ULTRASONIC MACHINING
    1) Power Supply
    2) Piezoelectric Transducer
    3) Work Piece
    4) Abrasive Slurry
    5) Velocity Transformer
    6) Tool
    7) Abrasive Gun
     Power Supply: This is used to power the machining process.
     Piezoelectric Transducer: In general transducer converts the electric
    signal to mechanical signal. Piezoelectric transducer is used to generate
    mechanical vibration in ultrasonic machining.

     Work Piece: An object (usually hard or brittle) being worked on with the
    tool or machine.

     Abrasive Slurry: Abrasive Slurry is delivered to interface between the


    work piece and the tool. As shown in the diagram below:
    -A water based slurry mostly of abrasive particle
    used as an abrasive slurry in this machining process.
    -Aluminum oxide , Silicon Carbide, Boron Carbide are
    used as an abrasive particle in this slurry.
     Velocity Transformer: It is used to hold the tool firmly.
     Tool: The tool should be design in such a way that when the operation is
    performed it does not go under brittle fracture. Hence tool should be made up of
    tough, strong and ductile material like steel, stainless steel or high stainless
    steel ,mild steel, copper, brass etc. The tool in Ultrasonic machining is made to
    vibrate with high frequency in the midst of the flowing slurry.
    - The shape of tool correspond to the shape to be produced in the work piece.
    - Tools are usually 25mm long.
    - Mass of tool should be minimum possible so that it does not absorb the ultrasonic
    energy.
    - Sometimes finishing or polishing operation on tool are required because their
    surface finish will be reproduced in work piece.

     Abrasive Gun: An abrasive gun is used to supply an abrasive slurry which is a


    mixture of abrasive grain and water in between tool-work piece interface under a
    definite pressure.
    WORKING PRINCIPLE OF ULTRASONIC MACHINING:
    • When the AC power is supplied with high frequency, the transducer
    starts vibrating longitudinally, which is then transmitted to the
    penetrating shaped tool which oscillates at high frequency, typically
    20-40KHz, in abrasive slurry. The tool is gradually fed with a
    uniform force and allowing the abrasive slurry to flow through
    between tool, workpiece interface. The high speed reciprocations
    of the tool and the flow of abrasive slurry results in the removal of
    thousands of microscopic grains from work material by abrasion.
    • The machining time of the ultrasonic machining entirely depends
    on the frequency of the vibrating tool, size of grain and the
    viscosity of the abrasive slurry.
    PROCESS PARAMETERS:

    1. Frequency of vibration. (19-25KHz)


    2. Amplitude of vibration. (15-50um)
    3. Feed pressure. (P)
    4. Feed force. (F)
    5. Abrasive size. (15-150um)
    6. Volume concentration of abrasive in slurry.
    7. Contact area of tool.
    APPLICATIONS OF ULTRASONIC MACHINING
     Used for machining round, square, irregular shaped holes and
    surface impression.
     It is used for coining and engraving application.
     It can be used to cut industrial diamonds.
     Used in machining of dies for wires drawing, punching and
    blanking operation.
     It enables a dentist to drill a hole of any shape on teeth.
     It is used in slicing and broaching hard materials .
    ADVANTAGES OF ULTRASONIC MACHINING
     The machining process is simple and economical and requires less
    time.
     This process is used for drilling both circular and non-circular holes
    in very hard materials like carbide, ceramics etc.
     Unlike conventional machining methods, ultrasonic machining
    produces no heat affected zone.
     Produce fine finished and structured results.
     It is not affected by the electrical or chemical characteristics of the
    work piece.
    DISADVANTAGES OF ULTRASONIC MACHINING
     It requires high power consumption and cost of tool is high, hence
    cost of machining is high.
     Tool wear is high hence shorter tool life.
     Low removal material rate(3-15mm^3/min).
     It is difficult to machine softer materials.
     Sharp corners can not be produced.
     The process is limited to the machined surface of a small size .

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