Supervised by: Dr.

Abdullah Alharbi
Created by: Majed Bamberok
 Content

 Introduction
 Working principles
 Machine components
 process parameters
 Material removal rate
 Applications
 Advantages and disadvantages
 Reference
 Rotary Ultrasonic
Machining (RUM) is a
non-traditional
machining process that
uses ultrasonic vibrations
and abrasive slurry to
machine hard and brittle
materials . It is a
promising technology
that has the potential to
revolutionize the
manufacturing industry.
❖ Rotary Ultrasonic Machining (RUM) is an advanced machining technique
used for cutting and drilling hard and brittle materials.
❖ RUM combines the principles of ultrasonic machining and rotary motion
to achieve highly precise and efficient material removal.
❖ It is widely employed in industries such as aerospace, automotive,
electronics, and medical, where the demand for machining brittle
materials is high.
 RUM is a mechanical material removal process used to machine hard or brittle
materials by combining the ultrasonic impacts (hammering, extraction, abrasion)
and the grinding action of the diamond abrasives bonded on the tool.
 The key difference between USM and RUM is that in RUM the tool also rotates and
the tool has metal bonded diamond abrasive particles.
 Rotary Ultrasonic Machining
(RUM) is regarded as an
enhancement of UM. The basic
principle is the combination of
conventional UM and CNC
grinding/milling process. The
difference between RUM and UM
is the vibrating object. With high
frequency micro-vibrations, UM
applies in vibrating the abrasive
slurry and makes the particles
remove the materials. The
uncontrollability of liquid and the
limitation of tools and equipment
restrict the further applications of
UM.
 Rotary ultrasonic machining technology
superimposes rotational movement with
20k-40k high frequency vibrations of Z-axis
direction. The rotating diamond-coated
tooltip will directly abrade the materials to
tiny particles and they will be carried away
by coolant. RUM changes continuous
cutting to intermittent movement via low
amplitude micro-oscillations;
therefore, the tool load and the thermal
impact could be significantly
reduced. Additionally, by side and vertical
directions of feed exercised
simultaneously, the material remove rate
could be enlarged.
1) Tool:
◦ The tool is a critical component in RUM and is typically made of a hard material, such
as steel or tungsten carbide, with a diamond abrasive coating.
◦ The tool's cutting edge comes into contact with the workpiece and is responsible for
material removal.
2) Fixture:
◦ The fixture holds the workpiece securely in place during the machining process.
◦ It ensures stability and proper alignment of the workpiece, preventing unwanted
movement or vibrations.
3) Spindle:
◦ The spindle provides the rotational motion to the tool.
◦ It rotates the tool at a controlled speed, allowing for precise material removal and
surface finish.
4) Ultrasonic Transducer:
◦ The ultrasonic transducer generates high-frequency vibrations in the range of 20 kHz
to 40 kHz.
◦ It is responsible for applying axial vibrations to the tool during the machining
process.
◦ The vibrations enhance the cutting action, facilitating material removal and reducing
cutting forces.
5) Coolant System:
◦ RUM generates heat during the machining process, which can affect the
workpiece and tool.
◦ A coolant system, such as a mixture of water and lubricants, is used to cool the
cutting zone, minimizing heat buildup and preventing thermal damage.
6) Control System:
◦ The control system oversees and regulates various parameters of the RUM
process.
◦ It manages the tool speed, feed rate, ultrasonic power, coolant flow, and other
parameters to ensure optimal machining conditions.
7) Chip Evacuation Mechanism:
◦ As material is removed during RUM, chips and debris are generated.
◦ A chip evacuation mechanism, such as suction or compressed air, is employed
to remove the chips from the cutting zone, maintaining a clear path for
machining.
 Vibration The frequency of the ultrasonic vibrations is typically between
frequency: 20 kHz and 40 kHz .

The amplitude of the ultrasonic vibrations is usually between 1

Amplitude:
and 50 microns .

The feed rate is the speed at which the cutting tool moves
Feed rate:
across the workpiece. It is typically between 0.1 and 1 mm/s .

A slurry containing abrasive particles is used as a coolant to

Coolant:
remove debris and cool the workpiece .

Tool The cutting tool is typically made of a hard, abrasive material

material: such as diamond .

Tool The geometry of the cutting tool can vary depending on the
geometry: application.
 Tool
Speed

During the machining

The tool speed can vary process, the tool speed
depending on the specific can be adjusted using
machining requirements, Determining the optimal
tool speed involves the machine's spindle
workpiece material, and control system to find
tooling used. There is no considering factors such
as material hardness, the balance between
fixed "number" that efficient cutting and
represents the tool speed cutting efficiency, heat
generation, and surface minimizing heat
in RUM as it can range generation. The actual
from a few hundred RPM finish requirements. It is
typically determined tool speed used will
(revolutions per minute) depend on the specific
to several thousand RPM. through experimentation,
taking into account the conditions and material
specific application and being machined.
desired outcomes.
 (MRR) in rotary ultrasonic machining (RUM) refers to the amount of
material that is removed during a given period of time. It is a crucial
parameter that determines the efficiency and productivity of the
machining process.

is influenced by several factors, including the feed rate, tool speed,

ultrasonic power, and the properties of the workpiece material.
Material Higher feed rates and tool speeds generally result in higher
Removal
material removal rates. Additionally, higher ultrasonic power can
enhance the cutting action and contribute to a higher MRR.
Rate
is typically measured in terms of volume or weight of material
removed per unit of time (e.g., cubic millimeters per minute or
grams per minute). The actual material removal rate in RUM will
vary based on the specific application, workpiece material, tooling,
and process parameters employed.

it is important to strike a balance between achieving a high

material removal rate and maintaining the desired surface finish
and dimensional accuracy. Increasing the material removal rate too
much can result in compromised surface quality or increased tool
wear.
Aerospace Automotive Optics
Industry Industry Industry
Electronics Medical Energy
Industry Industry Industry
 Suitable for machining hard and brittle materials, such as ceramics, glass,
composites, and hardened metals.
 Precise shaping and finishing of these materials
 Excellent surface finish due to the combination of rotary motion and
ultrasonic vibrations.
 Saving time and cost.
 Higher material removal rate compared to traditional grinding or milling
processes.
 The ultrasonic vibrations in RUM help in breaking up the chips and reducing
the contact between the tool and the workpiece. This leads to reduced tool
wear, extended tool life, and lower tooling costs.
 Complex and intricate geometries with high precision
 Requires specialized equipment that incorporates ultrasonic
transducers, rotary spindles, and control systems.
 Not effective for soft materials, as it is for hard and brittle
materials.
 Setting up and fine-tuning the process can be complex and
time-consuming.
 Large or bulky workpieces may pose challenges in
implementing RUM effectively.
 Rotary Ultrasonic Machining Ultrasonic Machining
Aspect
(RUM) (USM)
Machining Combination of rotary and ultrasonic
Vibrational motion of the tool
Mechanism motion

Cutting Grinding action through abrasive Chipping or erosion action through

Action particles abrasive slurry

Hard tool with abrasive working Soft tool made of materials like tool
Tooling
surface steel or titanium

Material Suitable for softer materials, less

Efficient for hard and brittle materials
Removal effective for hard ones

Aerospace, automotive, medical, Electronics, microfabrication, mold-

Applications
electronics, optics making, softer materials
 https://core.ac.uk/download/pdf/322824582.pdf
 https://slideplayer.com/slide/14591458/
 https://www.hit-tw.com/newsdetails.aspx?nid=262
 https://link.springer.com/referenceworkentry/10.100
7/978-1-4471-4670-4_76
 https://www.numerade.com