Production

Techniques-II
ME F313
ULTRA SONIC MACHINING (USM)
First machine was built in 1950s
Originally used for finishing of components produced
by EDM.
Best suited for electrically non-conducting,
semiconductive materials and brittle materials.
 Process of USM
A ductile and tough tool vibrating with a very high
frequency is pushed against the work surface with a
constant force.
A constant stream of abrasive slurry passes between the
tool and the work to provide abrasives.
The impact of hard abrasive grains fractures the hard and
brittle work surface, resulting in the removal of the work
material in the form of small particles.
Small fractured particles are carried away by continuous
flow of abrasive slurry .
The majority of the cutting action comes from an
ultrasonic (cyclic) force applied in addition to the other
forces.
Process of USM (contd.)
 Mechanics of USM
The reasons of material removal during USM are
believed to be,
1.The direct hammering of the abrasive on the work
surface by the tool (major factor).
2.The impact of the free abrasive particles on the work
surface.
3. The erosion due to cavitations.
4. Chemical action associated with the fluid used.
 Mechanics of USM contd.
A model proposed by M.C. Shaw, is well-accepted to
explain the material removal process.
This model considers the direct impact of tool on the
grains in contact with the workpiece.
The MRR is proportional to the volume of work
material per impact.
The MRR is proportional to the number of particles
making impact per cycles.
The MRR is proportional to the frequency (number of
cycles per unit time).
All impacts are identical.
All abrasive grains are identical and spherical.
Mechanics of USM contd.
 Mechanics of USM contd.
Consider the impact of a
rigid, spherical abrasive
grain of diameter d.
D is the diameter of the
indentation at any instant.
h is the corresponding
depth of penetration.
Mechanics of USM cont.
 Mechanics of USM contd.
The mean static feed force F
applied to the tool must be
equal to the mean force of the
tool on the grains.
Calculation of mean static feed
force (F) in terms of impact
force Fi in the duration of t.

Approximately mean static

feed force will be
 Mechanics of USM contd.
Calculation of total indentation
at the extreme bottom position
of the tool.
Indentation caused by the
grain on the tool ht.
Indentation caused by the
grain on the workpiece hw.
Total indentation at the
extreme bottom position of the
tool is
 Mechanics of USM contd.
Calculation of time
required to travel from A to
B.
The amplitude of
oscillation of the tool is A.
Average velocity of the tool
during the quarter cycle O
to B is .
Time required to travel
from A to B
 Mechanics of USM contd.
Now, mean static feed force F will be

Force per grain is

Approximate area of contact on the work surface

per grain is
 Mechanics of USM contd.
Maximum stress developed in the work surface

Depth of penetration is inversely proportional to the

flow stress of the material i.e.
 Mechanics of USM contd.
Since flow stress and the Brinell hardness are the
same, Maximum stress developed in the work
surface.

The number of grains acting is inversely proportional

to the square of the diameter of each grain for a
given area of the tool face.
Mechanics of USM contd.
 Mechanics of USM contd.
Maximum kinetic energy of the abrasive grain.
Mechanics of USM contd.
Mechanics of USM contd.
Variation of MRR with feed force
 Process Parameters
Frequency
Amplitude
Static loading (feed force)
Hardness ratio of tool and workpiece
Grain size
Concentration of abrasive slurry.
Variation of MRR with Frequency & Amplitude
Variation of MRR with Feed Rate &
Hardness Ratio
Variation of MRR with brittleness of
workpiece
Work material Relative MRR
Glass 100
Brass 6.6
Tungsten 4.8
Titanium 4.0
Steel 3.9
Chrome steel 1.4
Variation of MRR with Mean Grain Diameter
& Abrasive Concentration
Variation of MRR with Viscosity
Variation of Surface Finish on Grain Size
 Effect of USM on materials
The cutting force involved is very small, the process
produces no appreciable stress and heating. So,
material remains unaffected.
During cutting through a hole, chipping may occur at
the exit side of the hole. To avoid this, workpiece made
of brittle material is fastened to a base made of glass.
 Ultrasonic Machining Unit
The important components of ultrasonic machine:
1. The acoustic head
2. The feeding unit
3. The tool
4. The abrasive slurry and feeding unit
5. The body with work table
Ultrasonic Machining Unit contd
Acoustic Head
 Acoustic Head contd
The most important part of the machine.
It produces ultrasonic vibration to the tool.
Various components of acoustic head:
Generator: To supply high frequency electric current.
Transducer: To convert high frequency electric current
to high frequency mechanical vibration.
Holder: To hold the head.
Concentrator: To amplify vibration and transmit it to
the tool.
Concentrators
Concentrators contd
 Feeding Arrangements
To apply working force during machining.
To provide required depth of penetration.
Types of feeding mechanism:
Counterweight type
Spring type
Pneumatic and hydraulic type
Motor type.
Feeding Arrangements contd
Feeding Arrangements contd
Feeding Arrangements contd
 Tool
It is made of strong, ductile metal such as stainless
steel and low carbon steels.
Diameter of the circle circumscribed about the tool
should not be more than 1.5 to 2 times the diameter
of the end of the concentrator.
Tool should be as short and rigid as possible.
Side clearance should be maintained in the order of
0.06 mm to 0.36 mm, depending on the grain size of
abrasive.
 Abrasive Slurry
Common Abrasive: Boron carbide, silicon carbide,
corundum, diamond, boron
silicarbide.
Diamond dust is used only for cutting diamond and
rubies.
Commonly used fluid in the slurry: water, benzene,
glycerol etc.
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