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Manufacturing Technology (ME361) Lecture 12: Instructor: Shantanu Bhattacharya

Ultrasonic machining involves vibrating a tool at high frequency against a workpiece with an abrasive slurry between them. This causes the abrasive particles to impact the workpiece, removing small pieces and creating a machined surface. The rate of material removal depends on factors like frequency, amplitude, feed force, hardness ratio of tool and workpiece, abrasive grain size and slurry concentration. The optimal surface finish also depends on selecting the proper abrasive grain size.

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Sahil Sunda
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54 views

Manufacturing Technology (ME361) Lecture 12: Instructor: Shantanu Bhattacharya

Ultrasonic machining involves vibrating a tool at high frequency against a workpiece with an abrasive slurry between them. This causes the abrasive particles to impact the workpiece, removing small pieces and creating a machined surface. The rate of material removal depends on factors like frequency, amplitude, feed force, hardness ratio of tool and workpiece, abrasive grain size and slurry concentration. The optimal surface finish also depends on selecting the proper abrasive grain size.

Uploaded by

Sahil Sunda
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Manufacturing Technology

(ME361) Lecture 12
Instructor: Shantanu Bhattacharya
Ultrasonic Machining
• The use of Ultrasonics in Machine was first proposed by J.O.
Farrer in 1945.
• The first machine tool using ultrasonic principle was designed
in 1954.
• Originally, USM used to be for finishing operations on
components produced by electro-spark machining.
• This use became less important because of the development
in electric discharge machining.
• Ultrasonic machining also gained prominence in machining
electrically nonconducting, semiconducting and brittle
materials in the expanding electronic industry.
Basics of the USM process
• The basic USM process involves a tool ( made of a ductile and tough
material) vibrating with a very high frequency and a continuous flow of an
abrasive slurry in the small gap between the tool and the work piece.
• The tool is gradually fed with a uniform force.
• The impact of the hard abrasive grains fractures the hard and brittle work
surface, resulting in the removal of the work material in the form of small
wear particles.
• The tool material being tough and ductile wears out at a much slower rate.
Mechanics of USM
• The reasons for material removal in an USM process are believed to be:

1. The hammering of the abrasive particles on the work surface by the tool.
2. The impact of free abrasive particles on the work surface.
3. The erosion due to cavitation.
4. The chemical action associated with the fluid used.

• A no. of researchers have tried to develop the theories to predict the


characteristics of ultrasonic machining. The model proposed by M.C.
Shaw is generally well accepted and explains the material removal
process well.
M.C. Shaw’s model of USM mechanics
• In this model the direct impact of the tool on the grains
in contact with the work piece is taken into
consideration. Also, the assumptions made are:
1. The rate of work material removal is proportional to the
volume of the work material per impact.
2. The rate of work material removal is proportional to the
no. of particles making impact per cycle.
3. The rate of work material removal is proportional to the
frequency (no. of cycles per unit time).
4. All impacts are identical.
5. All abrasive grains are identical and spherical in shape.
USM process
• Thus, volume of work material removal rate
(Q)
Qα vZν
where, v = volume of the work material removal
per impact
Z = number of particles making impact
per cycle
ν = frequency
Mechanics of USM
Let us now consider the impact of a rigid,
spherical abrasive grain of diameter ‘d’ on the
work surface.
Mechanics of USM
Mechanics of USM
Mechanics of USM
Various Tool Position
during a USM cycle.

•The position ‘A’ indicates the instant the tool face touches the abrasive grain.
•The period of movement from ‘A’ to ‘B’ represents the impact.
•The indentations, caused by the grain on the tool and the work surface at the
extreme bottom position of the tool from the position ‘A’ to position ‘B’ is ‘h’ (the total
indentation).

Indentations on tool and work surface


at bottom position of the tool
Mechanics of USM process
Mechanics of USM
Mechanics of USM
Mechanics of USM process
Mechanics of USM
Mechanics of USM
Mechanics of USM
Mechanics of USM
Mechanics of USM
Mechanics of USM
Mechanics of USM
Mechanics of USM
Mechanics of USM
Mechanics of USM
Mechanics of USM
Mechanics of USM
Mechanics of USM
Mechanics of USM
Plot between MRR and Feed force

MRR increases with


increasing feed
force but after a
certain critical feed
force it decreases.
Process Parameters
The important parameters which affect the process are the:

1. Frequency.

2. Amplitude.

3. Static loading (feed force).


•With an increase in frequency of the
4. Hardness ratio of the tool and the workpiece. tool head the MRR should increase
proportionally. However, there is a
5. Grain size. slight variation in the MRR with
frequency.
6. Concentration of the abrasive in the slurry.
•When the amplitude of the
(a) (b) vibration increases the MRR is
expected to increase. The actual
nature of the variation is shown in
Fig. (b). There is some discrepancy in
the actual values again. This arises
from the fact that we calculated the
duration of penetration Δt by
considering average velocity
(A/(T/4)).
Process Parameters
• We already said that with an increase in static loading, the
mrr tends to increase. However, at higher force values of the
tool head due to grain crushing the mrr decreases.
• The ratio of workpiece hardness and tool hardness affects the
mrr quite significantly, and the characteristics is shown below.
• Apart from the hardness the brittleness of the work material
plays a very dominant role. The table below shows the
relative mrr for different work materials. As can be seen the
more brittle material is machined more rapidly.
Process Parameters
•MRR should also rise
proportionately with the mean grain
diameter ‘d’. When ‘d’ becomes too
large and approaches the magnitude
of amplitude ‘A’, the crushing
tendency increases.
•Concentration of the abrasives
directly controls the number of
grains producing impact per cycle.
MRR is proportional to C1/4 so after C
rises to 30% MRR increase is not very
fast.
• Apart from the process parameters some physical
properties (e.g. Viscosity) of the fluid used for the
slurry also affects the mrr. Experiments show that
mrr drops as viscosity increases.
•Although the MRR is a very important
consideration for judging the USM but so is the
surface finish.
Dependence of surface finish on grain
size
•The figure shows that the
surface finish is more sensitive
to grain size in case of glass
which is softer than tungsten
carbide.

•This is because in case of a


harder material the size of the
fragments dislodged through a
brittle fracture doe not
depend much on the size of
the impacting particles.

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