However, despite the above benefits, ultrasonic machining has a low material removal rate and gives low surface quality. Basic working principle, configuration, specification and classification of machine tools. The tool that is vibrated at ultrasonic frequency drives the abrasive to create a brittle breakage on the workpiece surface. The kinematic overlapping of the tool rotation with an additional. Oct 22, 2008 lecture series on manufacturing processes ii by prof. In this study, a novel chemicalassisted ultrasonic machining cusm method is introduced to overcome former disadvantages. Ultrasonic machining and its modelling and analysis 2. Chemical machining chemical machining method may be the oldest nontraditional machining method which is used to shape copper with citric acid in the ancient egypt in 2300 bc there are several factors contributing to the popularity of chemical machining processes as follow 1 chemical machining process is mature and well established.
A read is counted each time someone views a publication summary such as the title, abstract, and list of authors, clicks on a figure, or views or downloads the fulltext. Aug 07, 2017 this feature is not available right now. Ultrasonic technology poised for advance into general machining. Ultrasonic machining usm and ultrasonic machining tool. Part 2 deals with thermal machining processes for example, electric discharge machining, laser beam machining, electron beam machining.
Chemicalassisted ultrasonic machining of glass sciencedirect. Research on the machining principle and experinment of. This course will define the areas of application of nontraditional abrasive machining processes in the manufacturing industry. Ultrasonic horn design for ultrasonic machining technologies. Water jet and abrasive water jet machining youtube. Ultrasonic welding usw moderate pressure with ultrasonic oscillating motion 4 welding operation 50 types processes american welding society applications. Ultrasonic machining is a nontraditional process, in which abrasives contained in a slurry are driven against the work by a tool oscillating at low amplitude 25100 microns and high frequency 1530 khz. When very frequency vibrations are applied on to the. Advanced machining processes video course course outline there is a need for machine tools and processes which can accurately and easily machine the most difficultto machine. Slicing, coining, dicing, lapping, engraving, deburring, broaching, boring and trepanning operations are also practical.
Different graphical representation and the metal removal rate of the process. The shape and the dimensions of the workpiece depend on those of the tool. Ultrasonic machining is of particular interest for the cutting of nonconductive, brittle workpiece materials such as engineering ceramics. History the roots of ultrasonic technology can be traced back to research on the piezoelectric effect conducted by pierre curie around 1880. By 1954, the machine tools, using the ultrasonic principle, had been designed and constructed. Download ultrasonic machining process pdf at the end of the article. To get the chemical effect, a low concentration of hydrofluoric acid was added to the abrasive slurry. By using this method, metal should be removed so easily and also with a short time. So, you are seeing that machining this process of chip formation in metal cutting is effected by a relative motion between the tool and the workpiece achieved.
On the other hand, suppose i increase cutting speed, then production rate will be very high, but then the tool life will be very short, so that means, you have to do. 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. A mechanical conventional single cutting or ma action process can be combined with the respective machining phases of electrodischarge ed in. Reading will be suitably enjoyable in the manner of you in imitation of. Ultrasonic technology enables the economical machining of complex workpiece geometries in demanding hightech materials like ceramics, glass, corundum, tungsten carbide or even composites and notably the materion supremex material. Optisonic 1200 series large bridgestyle ultrasonic machining. Jun 22, 2010 introduction the technology of high power ultrasonics, already extensively applied at ewi in the fields of welding, solderingbrazing and additive manufacturing, is now being extended to the field of ultrasonic machining. Miyan ram 1709653 1 introduction ultrasonic machining usm is the removal of hard and brittle materials using an axially oscillating tool at ultrasonic frequencies 1820 khz during that oscillation, the abrasive slurry of b4c or sic is continuously fed into the machining zone between a soft tool brass or steel and the workpiece. In this process abrasives contained in the slurry are driven against the work by a tool oscillating at low amplitude 25100 microns and high frequency 1530 khz. Machining is the manufacturing process by which parts can be produced to the desired dimensions and surface finish from a blank by gradual removal of the. Unit ii mechanical energy based processes 10 abrasive jet machining water jet machining abrasive water jet machining ultrasonic machining. The top countries of suppliers are india, china, and vietnam, from which the percentage of ultrasonic machining supply is 1%, 97%, and 1% respectively. Non traditional abrasive machining processes ultrasonic. The tool travels vertically or orthogonal to the surface of the part at amplitudes of 0.
Particularly suited for very hard andorbrittle materials such asgraphite, glass, carbide, and ceramics. Unlike other nontraditional processes such as laser beam, and electrical discharge machining, etc. Particularly suited for very hard andorbrittle materials such asgraphite, glass, carbide, and. There were no cracks or microcracks developed during or after ultrasonic machining of advanced ceramics. Burr free holes and slots in hard, brittle materials.
Between the tool and workpiece, the machining zone is flooded with hard abrasive particles generally in the form of a water based slurry. Module 3 selection of manufacturing processes nptel. Usm offers a solution to the expanding need for machining. Non traditional manufacturing processes an overview introduction nontraditional manufacturing processes is defined as a group of processes that remove excess material by various techniques involving mechanical, thermal, electrical or chemical energy or combinations of these energies but do not use a sharp cutting tools as it needs to be.
Material removal processes categories of machining cutting involve single or multipoint cutting tools and processes turning, boring, drilling, tapping, milling, sawing, and broaching abrasive processes grinding, honing, lapping, ultrasonic machining advanced machining non traditional machining processs. Modern machining unit 5 modern machining method method structure 5. This is to certify that the report entitled study of parameters of ultrasonic machining submitted by sri sumit kumar samal in the fulfillment of the requirements for the award of bachelor of technology degree in mechanical engineering at the national. Traditional machining processes consist of turning, boring, drilling, reaming, threading, milling, shaping, planing, and broaching, as well as abrasive processes such as grinding, ultrasonic machining, lapping, and honing. Search by nptel course id, course name, lecture title, coordinator. Ultrasonic machining, water jet machining, abrasive water jet machining. In micro usm workpiece which is placed on the workpiece table vibrates at ultrasonic frequency 40 khz.
This paper presents a new method in machining of materials using cavitation process. The use of ultrasonics in machining was first proposed by l. Ion beam machining machine tool technology britannica. Welcome to the premier industrial source for ultrasonic machining services. The introduction of abrasives to the fluid jet enhances the. Rotary ultrasonic machining of hardtomachine materials by nikhil churi b. He found that asymmetrical crystals such as quartz and rochelle salt potassium. Named the tt51usa, it inherits the concept of aesthetic sheet metal design, userfriendly operation interface and machining precision.
Machine ii nptel electrical engineering this channel contains technical lectures on electrical. Mechanical engineering manufacturing processes ii nptel. Constructions, piping, pressure vessels, boilers and storage tanks, shipbuilding, aerospace, automobile and railroad welder manually controls placement of welding gun. Advanced nontraditional machining processes 303 work. Ultrasonic vibration machining can only be used on materials with a hardness value of at least 45 hrc rockwell hardness.
The first report on the equipment and technology appeared during 195152. Advanced processes include electrical and chemical means of material removal, as well as the use of abrasive jets, water. Kinematics of machines nptel online videos, courses. Today we are going to discuss on plasma arc machining process.
Ultrasonic machining introduction ultrasonic machining is a nontraditionalmechanical means of uniform stock materialremoval processit is applicable to both conductive andnonconductive materials. Wallace says the typical use of this machine would be conventional metalcutting most of the time, with the ultrasonic head loaded into the spindle for the parts and operations benefitting most from this capability. The figure shows the ultrasonic machining operation. So generally this gas molecules it consist of 2, 3 atoms okay. Its principle is to make the toolworkpiece interaction a microscopically nonmonotonic process to facilitate chip separation and to reduce machining forces. Applied and computationalmechanics4 2010 7988 ultrasonic horn design for ultrasonic machining technologies m. Ultra sonic machining has a vast application in modern world. Types of abrasive machining processes grinding honing lapping superfinishing polishing buffing abrasive water jet machining ultrasonic machining. Nptel syllabus advanced manufacturing processes web course course outline the course covers the details of the advanced machining theory and practices, advanced machining processes, advanced metal forming processes, advanced welding processes and advanced foundry processes. Apr 15, 20 ultrasonic machining introduction ultrasonic machining is a nontraditionalmechanical means of uniform stock materialremoval processit is applicable to both conductive andnonconductive materials. All aspects of mechanical, electrochemical and thermal processes are comprehensively covered. Ultrasonic vibrationassisted uva machining is a process which makes use of a microscale high frequency vibration applied to a cutting tool to improve the material removal effectiveness. Ultrasonic machining usm and waterjet machining wjm are typical examples of single action, mechanical non traditional machining processes. So this is the overview of ultrasonic machining i hope you like this article, to read this type of manufacturing stuff keeps visiting learnmechanica.
Need for nontraditional machining methods, classifications of modern machining processes, considerations in process selection, materials application, ultrasonic machining. What is hybrid manufacturing and classification of hybrid. It also includes micronanofinishing processes viz, abrasive flow finishing, magnetic abrasive finishing, etc. Difference between grinding and milling the abrasive grains in the wheel are much smaller and more numerous than the teeth on a milling cutter. Optisonic 800 series intermediate ultrasonic machining centers with 800 mm of xaxis travel. Non traditional machining jagadeesha t, assistant professor, med, national institute of technology, calicut introduction to ntm types of manufacturing processes. Processes likeabrasive jet machining water jet machininglaser beam machininghot machiningplasma arc machininghave also been included. Nptel video lectures, iit video lectures online, nptel youtube lectures, free video lectures, nptel online courses, youtube iit videos nptel courses. Paul,department of mechanical engineering, iit kharagpur.
This paper did a comprehensive analysis on ultrasonic machining mechanism in theory. On this channel you can get education and knowledge for general issues and topics. The optisonic 800 series ultrasonic machining centers feature 3, 4, or 5 axes of motion in a robust platform that incorporates the latest ultrasonic technology and 800mm of xaxis travel. Sharma, department of mechanical engineering, iit roorkee. Match listi machining process with listii associated medium and select the correct answer using the codes. What is hybrid manufacturing and classification of hybrid machining process technological improvement of machining processes can be achieved by combining different machining actions or phases to be used on the material being removed.
Influence of workpiece materials on machining performance in. In this process, the slurry is supplied to the gap between. Ultrasonic machining usm is an effective method for machining of hard brittle materials. A relatively small depth of material will become molten, and upon cooling, the structural. Ultrasonic machining, or strictly speaking the ultrasonic vibration machining, is a subtraction 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. Unconventional machining process need classification brief overview. Examples of conventional machining processes are turning, boring, milling, shaping, broaching, slotting, grinding etc. Non traditional abrasive machining processes ultrasonic, abrasive jet abrasive water jet machining. Ultrasonic machining parts, working, advantages full notes. Manufacturing processes can be broadly divided into two groups o primary manufacturing processes o secondary manufacturing processes.
Ultrasonic machining usm main parts, working principle. Understanding electrical discharge machining 29 automation and edm here is an example in which one may use their imagination to become more competitiveusing automatic production cells. Part 2 deals with thermal machining processes for example, electric discharge machining, laser beam machining, electron beam machining, etc. Ultrasonic machining offers an effective alternative for ultra precision machining of hard and brittle materials due to its unique characteristics. Lecture series on manufacturing processes ii by prof. Ultrasonic machining free download as powerpoint presentation. Ultrasonic machining usm is a mechanical material removal process used to erode holes and cavities in hard or brittle workpieces by using shaped tools, highfrequency mechanical motion, and an. Introduction to machine design, methodology, strength, rigidity, fracture, wear, and material considerations in design, use of standards, selection of materials and processes. Ultrasonic machining is ultrasonic machining processes, as being developed and applied at ewi, consist of the. This course would encompass a comprehensive study of metal cutting and machine tools.
Usm is mechanical material removal process or an abrasive process used to erode holes or cavities on hard or brittle workpiece by using shaped tools, high frequency mechanical motion and an abrasive slurry. The method is employed to machine hard and brittle materials which are either electrically conducting or nonconducting. Tongtai offers a new ultrasonic machining center, which is available from absolute machine tools inc. Influence of workpiece materials on machining performance in micro ultrasonic machining.
Today robots are available that can feed various machines, such as a milling machine, wire edm, and a ram edm. Mechanical engineering department indian institute of technology,kanpur 25th march, 2012 abstract a model is proposed for the mechanism of material removal in ultrasonic machining. To learn about various unconventional machining processes, the various process parameters and their influence on performance and their applications. Given this, nontraditional machining is widely utilized in responding to modern industrial problems. Micro ultrasonic machining musm is a method derived from conventional ultrasonic machining, in which a tool and free abrasives are used. Parts are burrfree with no residual stresses or thermal effects. In ibm a stream of charged atoms ions of an inert gas, such as argon, is accelerated in a vacuum by high energies and directed toward a solid workpiece. Principle of ultrasonic machining in the machining process, the tool, at some point, impacts on the largest grits, which are forced into the tool and workpiece. 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.
Ultrasonic machining is a nonconventional machining process. The ultrasonic machining center is also a fully capable conventional machining center. It is one of the types of nontraditional machining methods which produces circular, noncircular holes of very small size is ultrasonic machining method. The lectures would introduce the basic principles of material removal by impact erosion by use of abrasives against hard and brittle materials. The machining medium is solid grains suspended in an abrasive slurry in the former,while a fluid is employed in the wjm process. Ultrasonic machining is a mechanical material removal process that uses formed tools, vibration of high frequency and abrasive slurry mix. Modern machining processes presents unconventional machining methods which are gradually commercial acceptance. An analysis of material removal in ultrasonic machining due to. The technology of the manufacturing processes will be explained in detail. Tongtai t51usa ultrasonic machining center cutting tool. Nocnon traditional abrasive machining processes ultrasonic, abrasive jet abrasive water jet machining. Experimental study of micro ultrasonic machining process. Within a limited time of 10 hours, this course would elaborate on the theory of metal cutting supplemented with numerical problems. Micro ultrasonic machining micro usm, is one of the efficient material removal processes especially suitable for the micromachining of hard and brittle materials.
Ultrasonic machining is a mechanical type nontraditional machining process. A new nontraditional machining method using cavitation process. As the tool continues to move downwards, the force acting on these grits increases rapidly, therefore some of the grits may be fractured. The companies featured in the following listing offer a comprehensive range of ultrasonic machining services, as well as a variety of related products and services. Proceedings of the 15th international symposium on electromachining, isem 2007.
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