NON

CONVENTIONAL
MACHINING
(ULTRASONIC
MACHINING)
 Introduction
Classification of Non Conventional
Machining
Mechanical Processes Electro-Thermal
Abrasive Jet Machining Processes
Ultrasonic Machining Electro-Discharge
Abrasive Jet machining Machining
Abrasive Water Jet Laser Jet Machining
Machining Electron Beam
Machining
Electrochemical
Processes
Electrochemical
Machining Chemical Processes
Electrochemical Grinding Chemical Milling
Electro Jet Drilling Photochemical Milling
Ultrasonic Machining
Ultrasonic Machining(USM) is the removal of hard
and brittle materials using an axially oscillating tool
of desired shape at ultrasonic frequencies(18-25kHz)
and low amplitudes (15-40 m).
Between the tool and w/p, the machining zone is
flooded with hard abrasive particles generally in the
form of water based slurry.
The tool is pressed downward with a feed force to
obtain a negative of the tool at the w/p.
As tool vibrates over w/p, abrasive particles indent
the work surface, there will be brittle fracture and
hemispherical crater formation.
 Mechanism of Material
Removal
Material removal is primarily due to indentation
of hard abrasive grits on brittle w/p.
During indentation, due to Hertzian contact
stresses, cracks would develop just below the
contact site, then cracks would propagate and
ultimately lead to brittle fracture at that site.
Tools should be tough, strong and ductile.
Material removal may also be due to free flow
impact of abrasives and related solid-solid
impact erosion(insignificant).
 Illustration

Ultrasonic
Machine
Channels and holes
ultrasonically machined in a
polycrystalline silicon wafer.
 Machining System
The basic mechanical structure of an USM is similar
to a drill press.
The w/p is mounted on a vice, which can be located
at the desired position under the tool using a 2 axis
table .The table can be further lowered or raised to
accommodate work of different thickness.
The typical elements of USM are:
Slurry delivery and return system
Feed mechanism to provide a downward feed
force on the tool during machining
The transducer which generates the ultrasonic
vibration
The horn or concentrator which mechanically
amplifies the vibration to the required amplitude
Machining System
 Transducer
The ultrasonic vibrations are produced by the
transducer. The transducer is driven by suitable
signal generator followed by power amplifier.
The transducer for USM works on the following
principle
PIEZOELECTRIC EFFECT : Piezoelectric transducers
utilize crystals like quartz whose dimensions alter
when being subjected to electrostatic fields.
MAGNETOSTRICTIVE EFFECT : Magnetostrictive
transducers work on the principle that if a piece of
Ferro-magnetic material (like nickel) is magnetized,
then a change in dimension occurs.
 MAGNETOSTRICTOR
The magnetostrictor used, has a high frequency winding wound
on a magnetostrictor core and a special polarising winding
around an armature.
In order to obtain maximum amplification and good efficiency it
should be designed to operate at resonance where its natural
frequency must be equal to frequency of magnetic field.
Accordingly a magnetic field undergoing ultrasonic frequencies
causes corresponding changes in a ferromagnetic object placed
within its region of influence.
This effect is used to oscillate the USM tool, which is mounted at
the end of magnetostrictor at ultrasonic frequencies.
The main drawbacks of magnetostrictive transducer is that high
losses are encountered, low efficiency and need cooling. So
piezoelectric transducer are also used in USM machines.
 Mechanical Amplifi er/Horn
The elongation obtained at the resonance frequency is too small
for practical machining applications. The vibration amplitude is
increased by fitting an amplifier on the output end of the
magnetostrictor.
Larger amplitudes of 40-50m are desired for practical
applications which can be achieved using acoustic horns.
The horn or concentrator is a wave guide which amplifies and
concentrates the vibration to the tool from the transducer.
The horn or concentrator can be of different shapes like
Tapered or conical
Exponential
Stepped
Machining of tapered or stepped horn is much easier as
compared to the exponential one.
The choice of shape of acoustic horn determines the amplitude
of vibration.
 Tools
The tool does not exert any pressure on the work-piece
(drilling without drills), and is often made from a softer
material than the work-piece, say from brass, cold-
rolled steel, or stainless steel and wears only slightly.
Tool tips have high wear resistance and fatigue
strength.
For machining glass and WC, copper and chromium
silver steel tools are recommended.
During USM the tools are fed towards and held against
the workpiece by means of static pressure that has to
overcome the cutting resistance at the interface of the
tool and workpiece.
 Abrasive Slurry
Abrasive slurry is usually composed of 50 % (by
volume) fine abrasive grains of boron carbide,
aluminium oxide or silicon carbide in 50% water.
The abrasive slurry is circulated between the
oscillating tool and workpiece.
Under the effect of static force and ultrasonic vibration
the abrasive particles are hammered into the
workpiece surface causing mechanical chipping of
minute particles.
The slurry is pumped through the nozzle close to the
tool workpiece interface.
Slurry becomes less effective as the particles wear
and breakdown.
The slurry is continuously fed to the machining zone in
 Applications
Drilling
Ultrasonic sinking and contour
machining
Ultrasonic Polishing
Micro-ultrasonic machining
 Drilling
It is modified version of USM where a tool
bit is rotated against the work piece in a
similar fashion to conventional drilling. The
process is called rotary ultrasonic
machining(RUM).
It ensures high removal rates, lower tool
pressures for delicate parts, improved
deep hole drilling.
This allows the uninterrupted drilling of
small-diameter holes.
 Ultrasonic sinking &
contour machining
During USM sinking, the material
removal of the tool becomes
important. Under such conditions
the removal process is impossible.
Contouring USM employs simple
tools that are moved in accordance
to the contour required
 Ultrasonic polishing
It occurs by vibrating a brittle tool
material such as graphite or glass
into the workpiece at an ultrasonic
frequency and a relatively low
vibration amplitude
The fine abrasive particles, typically
removing 0.012 mm of material or
less .
 Micro-ultrasonic
machining
MUSM is a method that utilizes
workpiece vibration.
Using such a method microholes of 5-
m diameter on quartz, glass and
silicon have been produced using
tungsten carbide (WC) alloy
microtools.
 Factors Aff ecting Material
Removal Rate
TOOL OSCILLATION: The material removal rate increases with the
rise in amplitude of tool vibration. The kinetic energy of abrasive
rises at larger amplitudes , which enhances the mechanical
chipping action and consequently increases the removal rate.
But a high vibration amplitude may lead to occurrence of
splashing which causes a reduction of no. of active abrasive
grains and results in a decrease in material removal rate.
ABRASIVE GRAINS :The material removal rate rises at greater
grain sizes until the size reaches vibration amplitude, at which
stage, the material removal rate decreases .When the grain size
is large compared to the vibration amplitude there is difficulty of
abrasive renewal in the machining gap.
WORKPIECE IMPACT HARDNESS: The machining rate is affected
by the ratio of the tool hardness to the workpiece hardness. The
higher the ratio, the lower will be the material removal rate. For
this reason soft and tough materials are recommended for USM
tools.
 Factors Aff ecting Material
Removal Rate
TOOL SHAPE: An increase in tool area decreases the
machining rate due to the problem of adequately
distributing the abrasive slurry over the entire
machining zone.
FEED PRESSURE: The rise in the static feed pressure
enhances the machining rate upto a limiting condition
beyond which no further increase occurs.
HOLE DEPTH: There is decrease in material removal
rate with an increase in the hole depth. This is
because when the tool reaches deeper, the more
difficult and slower is the exchange of abrasives from
underneath the tool.
 Advantages
Machining any materials regardless of their
conductivity
USM apply to machining semi-conductor such as
silicon, germanium etc.
USM is suitable to precise machining brittle material.
USM does not produce electric, thermal, chemical
abnormal surface.
Can drill circular or non-circular holes in very hard
materials
Less stress because of its non-thermal characteristics
 Limitations
Under ideal conditions, penetration rates of 5
mm/min can be obtained.
Power units are usually 500-1000 W output.
Specific material removal rate on brittle
materials is 0.018 mm/Joule.
Normal hole tolerances are 7-25m and a
surface finish of 0.25 to 0.75m.
Works Satisfactory when w/p hardness is
greater than HRC40.
Aspect ratio(depth to dia.) 40:1
Disadvantages of USM
USM has low material removal rate.

Tool wears fast in USM.

Machining area and depth is restraint