R.K.

RANA [LECTURER]
M.Tech (P), B.Tech, LMIEI

YouTube.com/RamakantRana RamakantRana ULTRASONIC MACHINING

Ultrasonic Machining Process (USM)

Ultrasonic machining (USM) is a mechanical material removal process. It is used to erode material in the form of fine holes and cavities in hard or brittle workpiece through the use of formed tools, vibrations of high frequency along with the use of a suitable abrasive slurry slurry-mix. The Ultrasonic Machining (USM) process is suitable for machining brittle materials such as glass, ceramics and semiconduct semiconductors ors for increasingly complex operations to provide intricate shapes and workpiece profiles. The USM is a non-thermal thermal and non non-chemical chemical process which creates no change in the chemical, physical or metallurgical properties of the workpiece. It is therefore being eing widely used in the manufacturing of hard and brittle materials which are normally unfeasible to machine by the traditional methods. The cutting is actually performed by the abrasive particles which are suspended in the slurry1 (fluid). Ultrasonic machining hining accomplishes the material removal through the abrading2 action of the grit3-loaded loaded slurry which circulates between the tool and the workpiece. Small amplitudes and high frequency of vibrations are given to the tool, typically in the range of 1020 20 m at 2040 40 kHz. The hard abrasive particles in the slurry are accelerated towards the workpiece surface by the oscillating action of the tool - through repeated abrasions, the tool further machines a cavity of cross section identical to its own. The mater material ial removal takes place is the form of fine grains by shear deformation. Different mechanisms could be attributed to this material process such as brittle fracturing of the work material, impact action of abrasives, cavitation and chemical reaction due to the slurry. The workpiece shape and dimensional accuracy is directly dependent on the geometry of the tool. The schematic of ultrasonic material removal process is shown in following figure and the schematic of ultrasonic ltrasonic machine in figure figure.

1 2

Slurry: A suspension of insoluble particles Abrading: Rub hard or scrub 3 Grit: A hard coarse-grained grained siliceous sandstone

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R.K. RANA [LECTURER]

M.Tech (P), B.Tech, LMIEI

YouTube.com/RamakantRana RamakantRana ULTRASONIC MACHINING

Figure: Schematic ematic of Ultrasonic Material Removal Process

Figure: Schematic of Ultrasonic Machine Historical Development of US USM: The historical development of Ultrasonic Machining (USM) started through the research works in 1927. During investigating the ultrasonic grinding of abrasive powders, it was found that the surface of a container which was holding the suspended abrasives disintegrated as soon as the tip of an ultrasonically vibrating tra transducer nsducer was placed close to it. Interestingly, the shape of t the he cavity, thus produced accurately reproduced reprod the tip of the transducer. In the early 1950s industries started realizing its benefits and the production of ultrasonic machines began thereafter. A wide range of brittle materials, including glass, ceramics and diamond can be effectively machined through this process.

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R.K. RANA [LECTURER]

M.Tech (P), B.Tech, LMIEI

YouTube.com/RamakantRana RamakantRana ULTRASONIC MACHINING

Machine The basic mechanical structure of an USM is very similar to a drill press. However, it has additional features to carry ou out t USM of brittle work material. The workpiece is mounted on a vice, which can be located at the desired position under the tool using a 2 axis table. The table can further be lowered or raised to accommodate work of different thickness. The typical elements ements of an USM are (Following Figure Figure) Slurry urry delivery and return system Feed mechanism to provide a downward feed for force ce on the tool during machining The transducer, which generates the ultrasonic vibration The horn or concentrator, which mechanically amplifies the vibration to the required amplitude of 15 50 m and accommodates ccommodates the tool at its tip.

Figure: Schematic view of an Ultrasonic Machine The ultrasonic vibrations are produced by the transducer. The transducer is driven by suitable signal generator followed by power amplifier. The transducer for USM work works on the following principle

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M.Tech (P), B.Tech, LMIEI Piezoelectric effect Magnetostrictive effect Electrostrictive effect

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Magnetostrictive transducers are most popular an and robust amongst all. Following figure shows a typical magnetostrictive transducer along with horn. The horn or concentrator is a wave-guide, guide, which amplifies and concentrates the vibration to the tool from the transducer.

Figure: Working of horn as mechanical amplifier of amplitude of vibration The horn or concentrator can be of different shape like Tapered or conical Exponential Stepped Machining of tapered or stepped horn is much easier as compared to the exponential one. Following figure shows different horns used in USM USM.

Fig Figure: Different Horns used in USM

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R.K. RANA [LECTURER]

M.Tech (P), B.Tech, LMIEI

YouTube.com/RamakantRana RamakantRana ULTRASONIC MACHINING

USM Process: The USM process is performed using a desirable tool a along-with with abrasives slurry as a media. The cutting tool oscillates at high frequencies (typically 20 20-40 kHz) The shape of tool corresponds to the shape requirements in the workpiece. The abrasive grains are driven by the high speed reciprocations across the small gap, inbetween the tool and the workpiece. Uniform force is used to gradually feed the tool. The impact of abrasives is the energy source which is mainly res responsible ponsible in removal of material, through the form of small wear particles which are carried away by the abrasive slurry. Due to the abrasive action of particles, gradually wear of the tool occurs, thereby requiring the tool to be made of tough materials. Ultrasonic ltrasonic machining is a non non-traditional machining process. Following Figure briefly depicts the USM process.

Figure: The USM process In ultrasonic machining, a tool of desired shape vibrates at an ultrasonic frequency (19 ~ 25 kHz) with an amplitude of around 15 50 m over the workpiece. Generally the tool is pressed downward with a feed force, F. Between the tool and workpiece, the machining zone is flooded with hard abrasive particles generally in th the form of a water based slurry. As the tool vibrates es over the workpiece, the abrasive particles act as the indenters and indent both the work material and the tool. The abrasive particles, as they indent, the work material, would remove the same, particularly if the work material is brittle, due to crack initiation, propagation and brittle fracture of the material. Hence, USM is mainly used for machining brittle materials {which are poor conductors of electricity and thus cannot be processed by Electrochemical and Electro-Discharge ischarge machining (ECM and ED)} ED)}. www.CrazyProf.in www.RamakantRana.blogspot.com

R.K. RANA [LECTURER]

M.Tech (P), B.Tech, LMIEI

YouTube.com/RamakantRana RamakantRana ULTRASONIC MACHINING

Mechanism of Material Removal Removal: Although the USM process is commercially used since many decades the exact details of mechanism leading to the removal of fine materials is still to be understood. The research works done till date in understanding the process parameters have thrown light on some possible mechanisms. Through the investigations and the corresponding literatures, the main mechanisms responsible for the material removal in USM are as listed below: Mechanical abrasion: Occurs due to the hammering effect of abrasive particles on work piece through the tool. Impact: The freely moving particles impact with a certain velocity on the work piece resulting in micro chipping. Erosion: Due to cavitation effect of the abrasive slurry, erosion of th the e work surface occurs. Chemical: Due to fluid employed, chemical effect can come into consideration. It has been reported in the literature that among the above mentioned mechanisms, the first two are primarily responsible for major stock removal. The li literature terature reveals that erosion plays a lesser role in the removal of material for normal materials, however for the porous materials; it is observed that erosion due to cavitations is a significant factor. Advantages of USM In USM process, there are no phy physical, sical, chemical or thermal changes. The microstructures reveal that there are also no structural changes as the stresses induced are too less. The cutting forces being low, workpiece is unstressed, undistorted and free from heat effects. There is no direct contact of the tool and workpiece due to the slurry used, it makes it a wet cutting process. The surfaces produced are free from stress and damages. The process is free from burrs and distortions. The process is suitable for any material materials, s, irrespective of electrical conductivity The process is very much suitable for machining brittle materials The process offers good surface finish and structural integrity. Disadvantages / Limitations of USM Soft materials like lead and plastics are not suitable for machining by the USM process, since they tend to absorb the abrasive particles rather than to chip under their impact. The USM process consumes higher power and has lower material material-removal removal rates compared to traditional fabrication processes. The e tool wear rate in USM process is fast. The areas of machining and higher depths are the constraints in USM.

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R.K. RANA [LECTURER]

M.Tech (P), B.Tech, LMIEI

YouTube.com/RamakantRana RamakantRana ULTRASONIC MACHINING

As the USM process continuous, the lateral wear of the tool increases gradually and it tends to make the holes tapered. The sharp corners of the t tool ool get rounded off thereby requiring tool replacement essential for producing accurate blind holes. The accuracy of the machined surface gets lost due to setting up of strong lateral vibrations. This occurs if the axis of the tool and horn, which are braz brazed together, are not properly aligned with the transducer axis. In such a case, the tool needs to be redesigned. The holes produced in USM have a tendency to break out at the bottom owing to the static load and high amplitudes. While producing deeper holes through USM method, there is ineffective slurry circulation leading to presence of a fewer active grains under the tool face. Due to this, the bottom surfaces of blind holes tend to become slightly concave. Applications of USM USM process is used in mach machining hard and brittle metallic alloys, semiconductors, glass, ceramics, carbides etc. In machining of advanced ceramics for applications in auto auto-engine engine components. In machining, wire drawing, punching or blanking of small dies Machining ceramic substrates for drilling holes in borosilicate glass for the sensors used in electronic industries Drilling small holes in helicopter power transmission shafts and gears.

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R.K. RANA [LECTURER]

M.Tech (P), B.Tech, LMIEI

YouTube.com/RamakantRana RamakantRana ULTRASONIC MACHINING

Ultrasonic Machine and its Process Parameters

The basic ultrasonic equipment consists of the following elements: A generator for high frequency oscillations (Ultrasonic generator) An acoustic head consisting of transducer and trunk (shank) Tool and abrasive slurry elements The High Frequency Oscillating Current (OC) Generator Generator: The purpose of the OC generator is to produce high frequency oscillating currents. This generator transmits electrical power to the transducer which creates energy impulses in the ultrasonic range i.e. 18 18-20 KHz and converts them hem into mechanical vibrations. The primary function of the transducer is to convert electrical impulses into vertical and two dimensional strokes. The Acoustic Head This is the heart of the whole equipment and consists of two parts, A. The transducer, which converts the high frequency output of the generator into linear vibrations and B. The trunk, which mechanically amplifies the linear vibrations. Ultrasonic transducer The ultrasonic vibrations are produced by a transduc transducer er that is driven by the signal generator which gets further ther powered by an amplifier. The USM transducer works on the following principle: Piezo-electric effect4 Magneto-strictive strictive effect Electro-strictive strictive effect The function of ultrasonic transducer is to converts high frequency electrical impulses from the oscillator into mechanical vibrations. The periodicity of these vibrations periodically shortens and lengthens. For low power applications piezo piezo-electric transducers are used, whereas for high power applications magneto-strictive strictive transducers are commonly used. The trunk It is a critical link in the he ultrasonic machining system. It is known by several names such as shank, horn, concentrator and amplifier.
44

Piezo-Electric Effect: Electricity produced by mechanical pressure on certain crystals (notably quartz or Rochelle salt); alternatively, electrostatic stress produces a change in the linear dimensions of the crystal crystal.

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R.K. RANA [LECTURER]

M.Tech (P), B.Tech, LMIEI

YouTube.com/RamakantRana RamakantRana ULTRASONIC MACHINING

ifies and focuses vibrations of the transducer to the required intensity The trunk amplifies necessary enough for driving the tool. The increase in amplitude of vibrations at the tool end is obtained by reducing the cross section of the trunk. The Tool The tool is designed to provide the maximum amplitude of vibration at the free end. The selection of tool material is very important as the tool tip i is s subjected to vibration and it must not fail due to wear. The commonly used tool materials are brass, high speed steel, mild-steel, steel, silver, 5 stainless steel, tungsten carbide and monel . The tool is attached to the trunk (horn) by silver brazing or by hard soldering. At times it is fastened (screwed) with the trunk. The Abrasive Slurry The recommended slurry to be used in this process is a mi mixture of abrasive particles and liquid (water or kerosene). The slurry is pumped across the tool face. Slurry pump is a part of the machine-system. system. The properties requir required ed from the transport medium of abrasives include low viscosity, good wetting and high t thermal hermal conductivity. Water is a recommended medium for abrasive transportation which generally m meets eets most of the process requirement. Process Parameters in USM The determination of accurate process parameters which a affect ffect performance of ultrasonic machining ng is hard to determine as i it t works under multiple factors. The geometry and material properties of the work piece and tool make the system further complex to ascertain its performance characteristics. However, the performance of ultrasonic machining, to some extent is decided by the machining rate, machining accuracy, surface finish and tool wear. The process parameters which can affect the performance of USM are arranged into the following four major groups. In order to identify the process parameters in USM affecting the qualities of the machined surface, an Ishikawa cause effect ffect diagram as shown in Fig.1 Fig is constructed.

Monel: : An alloy of nickel and copper and other metals (such as iron and/or manganese and/or aluminium).

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R.K. RANA [LECTURER]

M.Tech (P), B.Tech, LMIEI

YouTube.com/RamakantRana RamakantRana ULTRASONIC MACHINING

Figure 1: Ishikawa kawa Cause and effect diagram showing Performance in USM The process parameters which govern the ultrasonic machining process have been identified and the same are listed below along with material parameters: Amplitude of vibration (ao) 15 50 m Frequency of vibration (f) 19 25 kHz Feed force (F) related to tool dimensions Feed pressure (p) 15 m 150 m Abrasive size Abrasive material - Al2O3 - SiC - B4C - Boronsilicarbide - Diamond Flow strength of work material Flow strength of the tool material Contact area of the tool A Volume concentration of abrasive in water slurry C

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R.K. RANA [LECTURER]

M.Tech (P), B.Tech, LMIEI

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Figure 2: Effect of machining parameters on MRR

Machine Parameters These are those parameters w which can be set on the machine. They include frequency and amplitude of the ultrasonic vibrations, the static load, work piece rotation and tool-head rotation.

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R.K. RANA [LECTURER]

M.Tech (P), B.Tech, LMIEI

YouTube.com/RamakantRana RamakantRana ULTRASONIC MACHINING

Abrasive Slurry Characteristics The type and size of the abrasives particles, its hardne hardness, ss, type of the fluid used as a carrier to form the abrasive slurry and the concentration of abrasive pa particles rticles in the slurry. Work piece properties The hardness, fracture characteristics, strength, work hardening tendency and fatigue properties of the work material also affect the process performance. Tool Material Properties and Tool Geometry The shape of the tool (solid or hollow), mechanical properties of the ma material terial used in tool-making making are some of the other parameters that may affect the USM process performance. Rotary Ultrasonic Machining (RUM) If the ultrasonic machining equipment possesses a rotary ry movement either at the ultrasonic head or at the worktable for drilling, milling, an and d threading operations, then it is termed as Rotary Ultrasonic Machine (RUM). In rotary ultrasonic machines the combination of rotational motion and axial vibrations (of tool) reduce friction between betwee the tool and the work piece material, provides uniform tool wear, a high degree of hole roundness and rapid removal of material from the cutting zone.

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