Module-3: ADVANCED MATERIAL REMOVAL PROCESSES

Lecture No-8
Ultrasonic Machine and its Process Parameters
The basic ultrasonic equipment consists of the following elements:

A generator for high frequency oscillations (Ultrasonic generator)

An acoustic head consisting of transducer and trunk (shank)

Tool and abrasive slurry elements

The High Frequency Oscillating Current (OC) Generator

The purpose of the OC generator is to produce high frequency oscillating currents. This
generator transmits electrical power to the transducer which creates energy impulses in
the ultrasonic range i.e. 18-20 KHz and converts them into mechanical vibrations. The
primary function of the transducer is to convert electrical impulses into vertical and twodimensional strokes.
The Acoustic Head
This is the heart of the whole equipment and consists of two parts,
(a) The transducer, which converts the high frequency output of the

generator

into linear vibrations and

(b) The trunk, which mechanically amplifies the linear vibrations.
Ultrasonic transducer
The ultrasonic vibrations are produced by a transducer that is driven by the signal
generator which gets further powered by an amplifier. The USM transducer works on the
following principle:

Piezo-electric effect

Magneto-strictive effect

Electro-strictive effect

The function of ultrasonic transducer is to converts high frequency electrical impulses

from

the oscillator into mechanical vibrations. The periodicity of these vibrations

periodically shortens and lengthens. For low power applications piezo-electric

transducers are used, whereas for high power applications magneto-strictive transducers
are commonly used.
The trunk
It is a critical link in the ultrasonic machining system. It is known by several names such
as shank, horn, concentrator and amplifier. The trunk amplifies and focuses vibrations of
the transducer to the required intensity necessary enough for driving the tool. The
increase in amplitude of vibrations at the tool end is obtained by reducing the cross
section of the trunk.
The Tool
The tool is designed to provide the maximum amplitude of vibration at the free end. The
selection of tool material is very important as the tool tip is subjected to vibration and it
must not fail due to wear. The commonly used tool materials are brass, high speed steel,
mild-steel, silver, stainless steel, tungsten carbide and monel. The tool is attached to the
trunk (horn) by silver brazing or by hard soldering. At times it is fastened (screwed) with
the trunk.

The Abrasive Slurry

The recommended slurry to be used in this process is a mixture of abrasive particles and
liquid (water or kerosene). The slurry is pumped across the tool face. Slurry pump is a
part of the machine-system. The properties required from the transport medium of
abrasives include low viscosity, good wetting and high thermal conductivity. Water is a
recommended medium for abrasive transportation which generally meets most of the
process requirement.

Process Parameters in USM

The determination of accurate process parameters which affect performance of ultrasonic
machining is hard to determine as it works under multiple factors. The geometry and
material properties of the work piece and tool make the system further complex to
ascertain its performance characteristics. However, the performance of ultrasonic
machining, to some extent is decided by the machining rate, machining accuracy, surface
finish and tool wear. The process parameters which can affect the performance of USM
are arranged into the following four major groups. In order to identify the process
parameters in USM affecting the qualities of the machined surface, an Ishikawa cause
effect diagram as shown in Fig. 3.8.1 is constructed.
Machine Parameters
These are those parameters which can be set on the machine. They include frequency and
amplitude of the ultrasonic vibrations, the static load, work piece rotation and tool-head
rotation.
Abrasive Slurry Characteristics
The type and size of the abrasives particles, its hardness, type of the fluid used as a
carrier to form the abrasive slurry and the concentration of abrasive particles in the slurry.
Work piece properties
The hardness, fracture characteristics, strength, work hardening tendency and fatigue
properties of the work material also affect the process performance.

Tool Material Properties and Tool Geometry

The shape of the tool (solid or hollow), mechanical properties of the material used in
tool-making are some of the other parameters that may affect the USM process
performance.

Rotary
R
Ultra
asonic Mach
hining (RUM
M)
Iff the ultrasonic machining equipm
ment possessses a rotar
ary movemeent either aat the
ultrasonic heaad or at the worktable
w
fo
or drilling, m
milling, and th
threading operations, theen it
is termed
d as Rotary Ultrasonic
U
Machine
M
(RU
UM). In rotary
ry ultrasonic
combinattion of rotatiional motion
n and axial vibrations
v
(off tool)

machhines

the

rreduce frictiion betweenn the

tool and the

t work pieece material,, provides un
niform tool wear, a higgh degree of hole rounddness
and rapid
d removal off material fro
om the cuttting zone.