Ultrasonic Machining Process (USM)
In this article, we will learn about Ultrasonic Machining Process: Construction, Working Principle Advantage & disadvantage. In Ultrasonic Machining Process the tool is vibrate machining at high frequency (i.e. 20 kHz). It contains key components such as a transducer, tool holder, and tool.
Construction and Working
Transducers coil with rounded Nickel lamination. In this coil, electricity is pumped at high frequency. The transducer converts this high-frequency current into mechanical vibration. This mechanical vibration is passed to the tool via the tool holder. The Tool is then axially vibrated at a frequency of 20 kHz to a distance of 0.05 mm.
The abrasive slurry is for Tool. Moves between the work surface. The abrasive slurry is a mixture of water with abrasive grains such as aluminum oxide, silicon carbide, or boron carbide. Due to the vibration of the tool, the abrasive grains in the slurry hit the work surface. Due to abrasion and erosion, the metal in the workpiece is expelled into very fine particles. Because of this, the Tool format is created on the work object. Feed to Tool should be slowed down. The maximum feed should be 0.1 mm / sec.
The tool should be 0.01 mm smaller than the hole size. The tool is made of a soft ductile material such as soft steel, copper card, and brass. It can work at 10.005 mm accuracy. The tool holder is made of stainless steel. Applications can be used to drill in hard and brittle materials.
(Ex. Manufacture ceramics, glass, carbide wire drawing dies. For hard metals, engraving, and broaching.
Advantages
- Easy machining in hard metals,
- Low-skilled workers are adequate.
- Low cost of production.
- Set up time is short.
Dis Advantages
- Slow removal of metal. This increases the machining time.
- Higher current costs.
- Metal cannot be removed by giving too much cut.
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