Scribd
Upload
13 views2 pages

Ultrasonic Machinings

Uploaded by

khankhalid0844
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
13 views2 pages

Ultrasonic Machinings

Uploaded by

khankhalid0844
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 2

Fabrication of microchannels through template-based

electrophoretically assisted micro-ultrasonic machining

Abstract:
This study presents a new method called template-based electrophoretically assisted micro-ultrasonic
machining (TBEPAMUSM) to create precise microchannels on tough materials like silicon and glass.
By applying a DC field, tiny abrasive particles stay in the machining area, allowing efficient and
accurate channel shaping. Tests showed that larger particles and higher ultrasonic power increased
material removal, while the right abrasive concentration and DC voltage improved both removal rate
and surface smoothness. The best settings were 70% ultrasonic power, 18 µm particle size, 18%
concentration, and 40 V DC.

Objectives:
 Explore how electrophoretic assistance USM can improve the presence of fine abrasive
particles in the machining area, enhancing precision.
 Investigate the impact of key process parameters—abrasive particle size, concentration,
ultrasonic power, and DC voltage—on material removal rate (MRR) and surface roughness
(SR).
 Identify optimal parameter settings that balance machining quality with efficiency for the
process.

Experimental Setup:
1) Power Part:

o Ultrasonic Power Supply: 300 W for ultrasonic vibrations.

o DC Power Supply: Provides an electrophoretic field with positive terminal on the microchannel
template and negative on the auxiliary electrode.

2) Machining Part:

o Ultrasonic Vibration System: Holds and vibrates the microchannel template.

o Microchannel Template: Attached to the ultrasonic system with adhesive.

o Annular Auxiliary Electrode: Positioned in the working-fluid tank with the workpiece.

3) Control Part:

o Industrial Computer, Data Cards, PI Controllers, Sensors: For monitoring and controlling
machining parameters.

4) Motion Part:

o 3D Micro Motion Platform: Provides precise movement with a range of 102 mm × 102 mm ×
25 mm and 0.1 μm resolution per axis.

5) This setup ensures high precision and stable machining conditions.


Findings:
 Abrasive Particle Size: Smaller abrasive particles (13 μm) reduced edge-chipping and
improved surface roughness (SR). Larger particles increased material removal rate (MRR) but
also worsened SR.

 Abrasive Concentration: A concentration of 18% balanced efficient material removal with


acceptable surface quality. Higher concentrations led to lower MRR due to excessive particle
collisions.

 Electrophoresis Voltage: A voltage of 40 V provided optimal particle movement, improving


MRR without significantly degrading SR.

 Ultrasonic Power: Higher ultrasonic power (90%) increased both MRR and SR, with 70%
power providing the best balance for quality machining.

Optimized parameters for minimal SR and maximum MRR were found to be 13 μm particle size, 40 V
electrophoresis voltage, 18% concentration, and 70% ultrasonic power.

Reference:
Haishan Lian, Cuiyuan Deng, Linpeng Zhang, Yuandong Mo, Junfeng He, Zhongning Guo, The
International Journal of Advanced Manufacturing Technology (2023) 129:5287–5302
https://doi.org/10.1007/s00170-023-12605-5

You might also like