ULTRASONIC MACHINING

The machines have

a power rating of
0.2-2.5'kW

The electronic
oscillator and
amplifier, also
known as the
generator, converts
the available
electrical energy of
low frequency to
high-frequency
power (20,000 cps)
which is supplied to
the transducer.

 The transducer operates

by magnetostriction.
The magnetostriction
effect is one in which
the material changes in
dimension in response
to a magnetic field.
Its main elements are an
electromagnet and a
stack of nickel plates.
Its main elements are an
electromagnet

 The high frequency power supply

activates the stack of magnetostictive
material which produces the vibratory
motion of the tool.
The magnitude of cutting of this
vibration is usually inadequate for
cutting purpose.

 Therefore, the tool is connected to the

transducer by means of a concentrator
which is simply a convergent wave
guide to produce the desired amplitude
at the tool end.
The amplitude of vibration is of the
order 0.01 to 0.06 mm.

 The lower limit of frequency is 15,000

cps. The upper limit of about 25,000
cps.
The transducer amplitude is limited the
strength of the magnetostrictive
material
Both frequency and amplitude are
adjustable

 The magnetostrictive material is

brazed to a connecting body monel
metal.
A removable tool holder is fastened to
the connecting body and is made of
monel metal or stainless steel

 The tool, which is smaller than the size

of the cavity by a few hundredths of a
millimeter and made of low-carbon or
stainless steel to the shape of the
desired cavity, is brazed or soldered to
the tool holder.

 All these parts, including the tool, act

as one elastic body, transmitting the
vibrations to the tip of the tool.

Abrasive Slurry
The abrasive is carried in a slurry
of water with 30% to 60% by
volume of abrasives.
When using large-area tools, the
concentration is held low to avoid
circulation difficulties.

 Boron carbide
Aluminum oxide
Silicon carbide
Boron Carbide is the fastest cutting abrasive
and it is quite commonly used.
Cost of boron carbide is 20 times higher than
Aluminum oxide or silicon carbide

 The abrasive slurry is circulated by

pumping, and requires cooling to
remove the generated heat to prevent it
from boiling in the gap and causing
the undesirable cavitation effect
caused by high temperature.
A refrigerated cooling system is used
to cool the abrasive slurry to a
temperature of 5-6C.

 A refrigerated cooling system is used

to cool the abrasive slurry to a
temperature of 5-6C.

 Ultrasonic machines are available for

various applications such as for
machining profile holes, trepanning
slicing, drilling, engraving, etc.

 Machines of different grades of

sensitivity of feed mechanisms are
required for machining different kinds
of materials.
For example, brittle materials require
a sensitive feed mechanism.

 Ultrasonic machines in general can

classified by their size and capacity
which also determines size of table,
tool travel and feed force, the type of
generators, type of acoustic head, and
machines universal or specific
application, abrasive slurry circulation
method, etc.

Relationship between MRR and ratio of

workpiece hardness and tool hardness

Machining Rate as a Function of Abrasive

Grain Size

Wear Ratio

volume of material removed from the work

Wear Ratio = --------------------------------------Volume of material eroded from the tool