In ultrasonic machining, the metal is removed by. Copyright ©Junying Metal Manufacturing Co., Limited, What is Ultrasonic Machining – Ultrasonic Machining Principle, Advantages and Application | CNCLATHING, Aluminum 6061-T6 vs 7075-T6 – Difference Between 6061-T6 and 7075-T6 | CNCLATHING, Difference Between T6 and T651 – Aluminum Tempers Designation System Explain | CNCLATHING, How to Calculate CNC Machining Time – CNC Machining Cycle Time Calculation | CNCLATHING, Different Types of Screws and Their Uses – Understanding Wood Screws, Machine Screws and More | CNCLATHING, Compare Different Fasteners: Difference Between Bolt, Screw, Rivet and Nut | CNCLATHING. 5 to 5 a. Grain material and size: The abrasive material should be at least hard as the workpiece material, it should not erode itself during ultrasonic machining. Due to this, the tool and the work piece never interact with each other. Gap between tool and work piece is controlled by servo mechanism. Looks like you’ve clipped this slide to already. Unconventional Machining Process Objective TYpe Questions. 21.3a. Principle of Ultrasonic Machining • During one strike, the tool moves down from its most upper remote position with a starting speed at zero, then it speeds up to finally reach the maximum speed at the mean position. – The rate of material removal is lower than most other machining techniques, – Not suitable for the mass production run, – Higher requirements for operator skills, – Unnecessary large particles may cause defects, – Drilling deep holes in parts are difficult, – Can only be used on materials with a hardness value of at least 45 HRC. Ultrasonic machining is a subtractive manufacturing process that removes material from the surface of a part through high frequency, low amplitude vibrations of a tool against the material surface in the presence of fine abrasive particles. i. d. none of these Brass or copper. iii. 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. b. Slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. Ultrasonic machining, also known as ultrasonic impact grinding, is a machining operation in which an abrasive slurry freely flows between the workpiece and a vibrating tool. In ultrasonic machining, the tool moves vertically or orthogonal to the surface of the part and fluctuate at the ultrasonic frequencies, the vibrations generated by the tool will project micro-sized abrasive particles to the part at a high speed, the particles mix with water or other liquids to form a slurry, which flowing between tool and workpiece, helps to grind away material from the surface of the piece. Between the tool and workpiece, the machining zone is ooded with hard abrasive particles generally in the form of a water based slurry. Language. D. Stainless steel. c. 10,000°C $(".your-captcha .wpcf7-not-valid-tip").html("Incorrect"); b. 3. In which of the following processes, the shape of tool is not same as that of cavity produced? d. ii & iii b. touches grain. (Ans:a) Which the following is true for Electrical Discharge machining (EDM)? Some light oil like transformer oil or kerosene oil is used as dielectric. They get scattered The smaller the grain size smoother the surface obtained, but it reduces material removal rate. b. 05, 0.5 d. Capable of producing sharp corners There is no heat generation in the ultrasonic machining process, so the workpiece will not deform and the physical properties of the part will remain uniform. Ultrasonic machining (USM) of materials Ultrasonic machining is an economically viable operation by which a hole or a cavity can be pierced in hard and brittle materials, whether electric conductive or not, using an axially oscillating tool. production fields of machining. Ultrasonic machining is a loose abrasive machining process that requires a very low force applied to the abrasive grain, which leads to reduced material requirements and minimal to no damage to the surface. The metal removal takes place due to erosion Only i Ultrasonic refers to waves of high frequency above the audible range of 20 kHz. Match List-I (Machining process) with List-II (Associated medium) and select the correct answer using the codes … 2,000°C During the operation, the tool and the ultrasonic machining part never interact with each other. If you continue browsing the site, you agree to the use of cookies on this website. 1. B. Ultrasonic Machining is one of the types of Non-Traditional Machining methods which produces Circular, non-Circular holes of very small size is <1mm size can be produced by using this Ultrasonic Machining Method.. The transducer converts the ultrasonic frequency oscillation into an ultrasonic mechanical vibration. Clipping is a handy way to collect important slides you want to go back to later. d. 0005, 0.005 2. The piezo-driven ultrasonic tooling system moves the diamond tool in a linear oscillatory motion with a unique frequency of 100 000 Hz, whereby the tool life is extended by orders of magnitude. In this process abrasives contained in the slurry are driven against the work by a tool oscillating at low amplitude (25–100 microns) and high frequency (15–30 kHz). Not for hard metals Answer: Option B . In Electron beam machining, as the electrons strikes the work piece 4. When very frequency vibrations are applied on to the tool, the tool is vibrating at a very high frequency. A. The vibration of the tool fixed to the end of the horn is ultrasonically vibrated by the amplitude amplifying rod (horn), forcing the abrasive suspension to continuously hit at high speed and polishing the surf… The tool is usually made from materials such as soft steels and nickel. C. Diamond. A higher amplitude is obtained by using a tool with a high transformation ratio, i.e. c. 005, 0.05 1. A. 9 In this idealized model, a cutting tool moves to the left along the workpiece at a constant velocity V, and a depth of cut to. Horn which is also known as tool holder, transfer this amplified vibration to tool which makes tool vibrate at ultrasonic frequency. Ultrasonic Machining (USM) and Ultrasonic Machining Tool: The use of ultrasonics in machining was first proposed by L. Balamuth in 1945. a. vacuum chamber In Electrical discharge machining, the temperature developed is of the order of movement of the tool produces a chip which moves up the face of the tool. While the tool moves, a slurry flows between it and the workpiece. The Impact force arising out of the vibration of the tool end and the flow of abrasive slurry causing thousand of microscopic grains to … The motion of the tool takes place vertically or orthogonal to the surface of the part. d. 14,000°C a. It has five main components in its working. a. … (function ($) { In this article, let’s take an overview of the ultrasonic machining process, covering its working principle, tools, advantages, disadvantages, and application. It is also known as Ultrasonic impact grinding is an operation that involves a vibrating tool fluctuating the ultrasonic frequencies in order to remove the material from the work piece. 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. You can change your ad preferences anytime. a. Burr free USM Machining accuracy and surface finish 1. Their kinetic energy is converted into heat The Electrical Discharge machining (EDM) process is a. Ultrasonic machining can cut glass, sapphire, engineered ceramics, silicon carbide, quartz, single-crystal materials, PCD, ferrite, graphite, glassy carbon, composites and piezoceramics, among other materials. b. Although manufacturing technologies are well developed for materials like metals and their alloys, considerable problems still exist in the fabrication of hard and brittle materials including ceramics and glass. 2. Edit. In cutting threads in co… The particles used in the abrasive fluid are usually boron carbide or silicon carbide as they are rigid than others. a. Ultrasonic Machining b. In ultrasonic machining, a tool of desired shape vibrates at an ultra-sonic frequency (19 - 25 kHz) with an amplitude of around 15 - 50 m over the workpiece. The vibrating tool, combined with the abrasive slurry, abrades the material uniformly, leaving a precise reverse image of the tool shape. (Ans:a). This tool can fit in any of your existing machines. b. i &ii The positive ions moves towards the tool (cathode) and negative ions move towards the workpiece. – Idea choice for ceramic matrix composites, glass, quartz, diamonds, PCD, etc. (Ans:c) There are a ton of subtractive production methods, such as CNC turning, milling, and more. Erosion takes place both on Work piece and the tool. 2. In ultrasonic machining, a liquid filled with abrasive material flows through over the work piece, and the work tool vibrates against the abrasives. a machining unit for shaping various solid materials. The force of tool varies as it moves down. • Then the tool slows down its speed … c. Direct contact machining In ultrasonic machining, the tool moves vertically or orthogonal to the surface of the part and fluctuate at the ultrasonic frequencies, the vibrations generated by the tool will project micro-sized abrasive particles to the part at a high speed, the particles mix with water or other liquids to form a slurry, which flowing between tool and workpiece, helps to grind away material from the surface of the piece. c. The electrode (tool) is made of graphite or copper. Solution(By Examveda Team) The tool material should be such that indentation by the abrasive grits does not lead to brittle failure. As the tool vibrates, it makes abrasive particle to vibrate at this high frequency. (Ans:c) Slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. The range of obtainable shapes can be increased by moving the workpiece during cutting. 5. Which of the following is not true in case of Electrical discharge machining (EDM)? Machining glass, ceramic, tungsten and other hard carbide, gemstones such as synthetic ruby. 1. 4. a. In an ultrasonic machine tool, ultrasonic vibrations are transmitted to a tool and then to the material through abrasive particles in a slurry. If you continue browsing the site, you agree to the use of cookies on this website. Ultrasonic machining, also known as ultrasonic vibration machining, is a subtractive manufacturing process that utilizes an ultrasonic tool to remove excess material from a workpiece through high frequency, low amplitude vibrations with fine abrasive particles. Also Read: Ultrasonic Machining (USM) – Main Parts, Working Principle, Advantages and Disadvantages with Application the ratio of transducer/tool diameter 27, 39. 1. It is very useful for materials that are brittle and sensitive. 6. Ultrasonic Machining . (Ans:c) – Suitable for almost all types of materials, – Do not need heating or cooling during the machining process, – Capable to offer a higher tolerance than many other processes. In Electron beam machining, workpiece is held in This abrasive particle strikes to the work piece and remove metal form it. d. Electro-chemical etching takes place See our Privacy Policy and User Agreement for details. Despite all this, ultrasonic machining also has some shortcomings. (Ans:d) During ultrasonic machining, the metal removal is achieved by (a) high frequency eddy currents (b) high frequency sound waves (c) hammering action of abrasive particles (d) rubbing action between tool and workpiece 2. Ultrasonic machining is a method of grinding that uses an abrasive liquid rather than direct tool contact. Ultrasonic machining is a nontraditional process. In ultrasonic machining, tool is made of. Ultrasonic Machining PPT with PDF Seminar Report: Ultrasonic machining is a mechanical material removal process that uses formed tools, vibration of high frequency and abrasive slurry mix.It works on a frequency of more than 20000 Hz. With a number of manufacturing methods, manufacturers often want to find the best way for the specific project. Using abrasive slurry between the tool and work. d. The size of impression on work piece is exactly the same as that on electrode (tool). 3. Tungsten carbide. B. – Machining ceramics, carbides, glass, precious stones, and hardened steels, – Create microelectromechanical system components such as micro-structured glass wafers, – Manufacture parts with high precision and tolerance. Unlike other manufacturing techniques, the ultrasonic machining process has unique benefits. We use your LinkedIn profile and activity data to personalize ads and to show you more relevant ads. In Ultrasonic machining, the tool moves a. moves in transverse direction b. moves in longitudinal direction c. vibrates in transverse direction d. vibrates in longitudinal direction (Ans:d) 33. Subscribe Subscribed ... by up to 40 % in comparison to conventional machining. 7. Ultrasonic machining is a contemporary manufacturing method usually employed for processing materials with higher hardness/brittleness such as quartz, semiconductor materials, ceramics etc. c. electrolyte Now customize the name of a clipboard to store your clips. It also does not need to change the temperature. })(jQuery); Junying Metal Manufacturing has developed high-level manufacturing technique in In ultrasonic machining processes, a formed tool made of ductile and tough material, having the shape of the cavity to be machined is made to vibrate against the workpiece surface, and between the two, continuous flow of slurry of abrasive particles is maintained. b. dielectric medium Most grinding processes involve a work tool making direct contact with a work piece in order to gouge material away. By 1954, the machine tools, using the ultrasonic principle, had been designed and constructed. Tool moves downward from it m ean position which . The process involves an abrasive slurry that runs between the tool and the work piece. Ultrasonic machining is usually used to cut non-conductive, brittle materials because it does not produce thermal damage or significant levels of residual stress on the part, which is critical for the machining of brittle materials. 2. The amplitude, ξ, of the ultrasonic tool before machining can be measured by using either an accelerometer , an eddy current probe 30, 85, a laser dopplermeter or laser speckle pattern interferometer . 6,000°C As a result of the compact design, the UTS2 can easily be integrated into any commercially available precision and ultra-precision machine. The simplicity of the process makes it economical for a wide range of applications such as: 1. In Electrical discharge machining (EDM), the spark gap is kept between ___mm to___mm. Any electrical conductor can be machined by this method. Introducing round holes and holes of any shape for which a tool can be made. c. Mechanical erosion in work piece takes place The tool is vibrating at high frequency and low amplitude in … See our User Agreement and Privacy Policy. Acoustech adds ultrasonic vibration to a standard machining center and cutting tool via a device that is essentially a toolholder with the ultrasonics built in. c. i,ii & iii The controlled microscopic oscillation added to the tool reduces friction to reduce cutting force, increasing the life and effectiveness of the tool. Direct contact of tool with the work C. Maintaining an electrolyte between the work and tool in a very small gap between the two D. Erosion caused by rapidly recurring spark discharges between the tool and work Answer: Option A It differs from most other machining operations because very little heat is produced. The machined surface produced by ultrasonic machining is found to be free from any surface defects (heat affected zone, cracks, recast layer, etc.) The material to be processed will affect the selection of the machining process. The tool oscillates with small amplitude of … It is capable of removing materials from almost all types of materials, whether strong or brittle parts, such as ceramic. ii. Generally the tool is pressed downward with a feed force. A distinction is made between all-purpose and specialized ultrasonic machine tools. (Ans:a) This is the whole working process of ultrasonic machining. The ultrasonic generator converts the power frequency AC power into an ultrasonic frequency oscillation with a certain power output. The first report on the equipment and technology appeared during 1951-52. Machining and Thermal aspects (MGU S8 ME), No public clipboards found for this slide. To analyze this process in detail, a 2-D model of it is represented in Fig. Speed up all the machining jobs with ultrasonic tools. As the potential difference is applied across the electrode, the movement of ions starts in between the tool and w/p. In machining operations like drilling, grinding, profiling and milling operations on all materials both conducting and non-conducting. Their superior physical and mechanical properties lead to long machining cycle and high production cost. Ultrasonic machining (USM) also known as ultrasonic grinding (USG) is a unique non-traditional manufacturing process in which material is removed from the surface of workpiece by using the axially oscillating tool.