Comment document.getElementById("comment").setAttribute( "id", "ace308bedaf6b337e3ffc9544e03419e" );document.getElementById("jc7cf923c9").setAttribute( "id", "comment" ); Today we will learn about ultrasonic machining, principle, working, equipment’s, application, advantages and disadvantages with its diagram. Ultrasonic is seldom used in upstream hydrocarbon process stream for level measurement; it might be used in atmospheric utilities applications. So a high frequency high voltage power supply require for this process. Ultrasonic machine generates high frequency vibrating wave of frequency about 20000 to 30000 Hz and amplitude about 25-50 micron. Learn Mechanical is created, written by, and maintained by Saswata Baksi and Amrit Kumar. A water-based slurry of abrasive particle used as an abrasive slurry in this machining. Silicon carbide, aluminum oxide, boron carbide are used as abrasive particle in this slurry. USM is grouped under the mechanical group NTM processes. 5. No thermal effects on the workpiece are required. This is the whole working process of ultrasonic machining. Abrasive like Aluminium Oxide, Silicon Carbide can be used. ATTENTION: Don't forget to share this stuff on your favorite social media platform, and be a part of #Spread_the_knowledge. The construction of the machine and its elements depends critically on the process being performed by the tool. During ultrasonic machining, the workpiece’s temperature will remain the same. The materials for ultrasonically welded components are possibly the most important limitation - the process works best when both components are made from similar amorphous polymers. The size of the ca… This process is used for drilling both circular and non-circular holes in 2. very hard materials like carbide, ceramics, etc.3. Meaning of Ultrasonic Machining (USM): Ultrasonic waves are sound waves which propagate at frequency of 18 to 30 kc/sec and are thus beyond the human ear to respond. Advantages and limitations of Ultrasonic Machining USM Advantages. This leads indentation of abrasive particle to brittle work piece and removes metal from the contact surface. The mechanical vibration generated by transducer is passes through booster which amplify it and supply to the horn. Component materials. It is used machining of machining non-conductive hard material which cannot be machined by ECM or EDM due to poor conductivity. Disadvantages of Ultrasonic Machining Process (USM): Only brittle materials can be machinable. Ultrasonic Machining . As we know, transducer is a device which converts electric single into mechanical vibration. Ultrasonic machining is able to produce high-tolerance parts because there is no distortion of the worked material. For making the object, the raw material is pushed into a die to provide it with the desired shape. Drilling the round holes of any shape.3. What is the gap is Maintaining between the tool surface and workpiece surface ? Abrasive particles are responsible to cut the material. The high rate of metal removal and so on. Low penetration rate. Ultrasonic Machining (USM) also called as ultrasonic vibration machining is a machining process in which material is removed from the surface of a part by low amplitude and high frequency vibration of a tool against surface of material in the presence of abrasive particles. 1. The tool used in ultrasonic machining should be such that indentation by abrasive particle, does not leads to brittle fracture of it. The motion of the tool takes place vertically or orthogonal to the surface of the part. Compared to conventional machining (CM), ultrasonic vibration-assisted machining (UVAM) with high-frequency and small-amplitude has exhibited good cutting performances for advanced materials. The limitations of machining process are as follows. Ductile metal cannot be machine by this method. This low frequency current converts into high frequency current through some electrical equipment. The depth of the defect is determined by the ratio D/Ep There are two methods of receiving the ultrasound waveform. This machining is used to machine hard and brittle material like carbide, ceramic, glass etc. Waves are generated using magnetostrictive effects which are further converted into mechanical vibration. The booster amplify this high frequency vibration and send to horn. Difficulties are encountered in machining softer materials 6. Profiling the holes. ... Write the typical applications of ultrasonic machining. If you have any query regarding this article, ask by commenting. As the diagram showing the first is connected to the power supply. As shown in below figure (left) : A probesends a sound wave into a test material. xi. Hence 100% inspection of the component is required. It is used for:1. 2. The tool has the same shape as the cavity to be machined. Your email address will not be published. If you like this article, don’t forget to share it on your social networks. Aluminum oxide, Silicon carbide, Boron carbide are used as an abrasive particle in this slurry. Out of all the non-traditional machining methods, ultrasonic machining requires lower specific cutting energy. These limitations of traditional machining can be eliminated by non-traditional machining process. Attenuation. The Impact force arising out of the vibration of the tool end and the flow of abrasive slurry causing thousand of microscopic grains to remove from work material by abrasion. The process is limited to the machined surface of a small size. It works as follow. Limitations of Ultrasonic Machining (USM). The initial equipment cost is higher than the conventional machine tools. ... As the name implies, this process uses ultrasonic vibration energy for machining. This process is best suited for brittle materials.4. Advantages and disadvantages of Ultrasonic Machining 2. Ultrasonic machining [USM] is a modern metal removal process for brittle and hard materials which may be either conducting or non-conducting, by using high … Ultrasonic machining (USM) is a nontraditional mechanical machining process and can be used in many applications. Thus the tool is made by tough, strong and ductile materials like steel, stainless steel etc. Different Metals Used in Automobile Engine, Abrasive Jet Machining: Principle, Working, Equipment’s, Application, Advantages and Disadvantages, Drum Brake: One of the Common Braking System. It is State the principle of ultrasonic machining process? 1.2 Advantages of Machining Process: A high surface finish can be obtained. The model proposed by M.C. It should have high endurance limit. If a workpiece is sensitive to thermal fluctuates, it can be safely altered using this machining process. This is essential. The cost of tooling is also high. As the tool vibrates it is pressed on the work surface with light force and allowing the abrasive slurry to flow through between tool-workpiece interface. This abrasive particle strikes to the work piece and remove metal form it. It can machine only hard material. High power consumption. As the tool vibrates, it makes abrasive particle to vibrate at this high frequency. The accuracy of the components produce is dependent on the efficiency of the operator. Electro Discharge Machining (EDM) is an electro-thermal and non-conventional machining process, where material is removed due to thermal energy of the spark. The Ultrasonic Machine consists of different parts as follows: To starts, the machining process power is required. 7. The major function of this process is that the brittle materials […], In this article, I'll show you everything you need to know about the Die Casting Process. The Limitations Of Conventional Machining Processes Engineering Essay Introduction. Ultrasonic Machining is a non-traditional process, in which abrasives contained in a slurry are driven against the work by a tool oscillating at low amplitude (25-100 microns) and high frequency (15-30 kHz). A number of researchers have tried to develop the theories to predict the characteristics of ultrasonic machining. the ultrasonic machining of brittle materials. The ultrasonic machining process can be employed to machine precision micro-features, circular and non-circular micro-holes and blind micro-cavities. No heat is generated in case of ultrasonic machining and it … It transfers amplified vibration from booster to the tool. A slurry delivery and return mechanism is also used in USM. Your email address will not be published. As the machines perform several techniques like: It consists of an electromechanical transducer connected to the AC supply. It works on the same principle of ultrasonic welding. Ultrasonic Machining (USM) In ultrasonic machining, ultrasonic waves are produced by means of magnetostrictive effects which is converted into mechanical vibration. Physical properties of machined parts will remain uniform throughout. Horn which is also known as tool holder, transfer this amplified vibration to tool which makes tool vibrate at ultrasonic frequency. 9.2.1 briefly depicts the USM process. Reflection and 2. 44. This machining process comes into existence in 1950 for finishing EDM surface. An electromechanical transducer connected to the AC supply. Process of […]. The applications of Ultrasonic Machining are: The advantages of Ultrasonic Machining are: Here are some disadvantages of Ultrasonic Machining: So this is the overview of Ultrasonic machining I hope you like this article, to read this type of Manufacturing stuff keeps visiting LearnMechanica.Com. 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