Pdf ultrasonic machining effects on the surface finish. An experimental study on ultrasonic machining of an. Advanced welding processes details of electron beam welding ebw laser beam welding lbw ultrasonic welding usw 6 4. 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.
Pdf ultrasonic machining effects on the surface finish and. Unconventional machining process nov,dec2014, may 2014 r2008,unconventional machining process may 2014 r2008,2010,unconventional machining process nov,dec20,unconventional machining process dec2012,unconventional machining process ap,may2008,unconventional machining process may2009,unconventional machining process nov,dec2009,unconventional machining process nov,dec2010. Unconventional machining process anna university question paper. This is to certify that the thesis entitled, optimization of the machining parameters for ultrasonic vibration assisted turning of hard material submitted by mr. He found that asymmetrical crystals such as quartz and rochelle salt potassium. In ultrasonic machining, a liquid filled with abrasive material flows through over the work piece, and the work tool vibrates against the abrasives. 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. The experiment compared this ultrasonic machining process with the common machining process in. Ultrasonic machining is a mechanical type nontraditional machining process. Ultrasonic technology machines hard, brittle materials accurately and easily. By using this method, metal should be removed so easily and also with a short time. Ultrasonic machining centers can perform both conventional and ultrasonic machining operations.
Advanced nontraditional machining processes 303 work. Thanks for using our companys products, in order to fully make. Abrasive waterjet cutting of microelectronic components mohamed hashish flow international corporation kent, wa abstract a new process for cutting and singulating chips has been commercially introduced. Grinding ultrasonic machining chemical machining electrochemical machining electricaldischarge machining highenergybeam. Erich bertsche, product manager for advanced technologies for. The shape and the dimensions of the workpiece depend on those of the tool. Ultrasonic enhancement of an electrochemical machining process. Unlike other nontraditional processes such as laser beam, and electrical discharge machining, etc. Its principle is to make the toolworkpiece interaction a microscopically nonmonotonic process to facilitate chip separation and to reduce machining forces. Ultrasonic machining is of particular interest for the cutting of nonconductive, brittle workpiece materials such as engineering ceramics. Ultrasonic machining involves imparting ultrasonic vibrations of frequency 20 khz to a tool to effect material removal.
Dec 01, 2011 ultrasonic machining is an easytouse technology that allows a mold manufacturer to machine very hard or brittle materials with flexibility and accuracy. Ultrasonic machining national institute of technology. Particularly suited for very hard andorbrittle materials such asgraphite, glass, carbide, and. Ultrasonic technology poised for advance into general. 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. Ultrasonic machining is a mechanical material removal process that uses formed tools, vibration of high frequency and abrasive slurry mix. Research on the machining principle and experinment of. This process is based on cutting contoured lines with finebeam 0. Electrochemical machining works on the principles of electrolysis. Ultrasonic machining ultrasonics have been used in several ways for machining metals. The ultrasonic machining center is also a fully capable conventional machining center. Micro ultrasonic machining musm is a method derived from conventional ultrasonic machining, in which a tool and free abrasives are used.
Nov 29, 2016 ultrasonic machining involves imparting ultrasonic vibrations of frequency 20 khz to a tool to effect material removal. Ultra sonic machining has a vast application in modern world. Water jet and abrasive water jet machining youtube. The machining characteristics that are being investigated are tool wear rate and the quality of the. Lecture series on manufacturing processes ii by prof. Complete machining of components with rotationalsymmetric properties incl. Ultrasonic cutting of cheese and apples effect on quality attributes during storage by gulcin yildiz thesis submitted in partial fulfillment of the requirements for the degree of master of science in food science and human nutrition with a concentration in food science in the graduate college of the. Unconventional machining process anna university question. Particularly suited for very hard andorbrittle materials such asgraphite, glass, carbide, and ceramics. Sharma, department of mechanical engineering, iit roorkee. Non traditional machining processes, also called advanced manufacturing processes, are employed where traditional machining processes are not feasible, satisfactory or economical due to special reasons as. Ultrasonics have been used in several ways for machining metals. The machined surface produced by ultrasonic machining is found to be free from any surface defects heat affected zone, cracks, recast layer, etc. Electron beam machining ebm laser beam machining lbm processes 2.
Ultrasonic horn design for ultrasonic machining technologies. Applied and computationalmechanics4 2010 7988 ultrasonic horn design for ultrasonic machining technologies m. Unconventional machining process nov,dec2014, may 2014 r2008,unconventional machining process may 2014 r2008,2010,unconventional machining process nov,dec20,unconventional machining process dec2012,unconventional machining process ap,may2008,unconventional machining process may2009,unconventional machining process nov,dec2009,unconventional machining process. As the tool continues to move downwards, the force acting on these grits increases rapidly, therefore some of the grits may be fractured.
Electrochemical machining, ultrasonic processing, hybrid machining processes, depassivation 1. Usm is grouped under the mechanical group ntm processes. The tool that is vibrated at ultrasonic frequency drives the abrasive to create a brittle breakage on the workpiece surface. The main working principle of chemical machining is chemical etching. A new nontraditional machining method using cavitation process. Different graphical representation and the metal removal rate of the process. Aug 07, 2017 this feature is not available right now.
Optimization of the machining parameters for ultrasonic. A new nontraditional machining method using cavitation. Paul,department of mechanical engineering, iit kharagpur. Usm offers a solution to the expanding need for machining. It is important to make provisions to control the dust created by the machining operation. To get the chemical effect, a low concentration of hydrofluoric acid was added to the abrasive slurry.
This paper presents a new method in machining of materials using cavitation process. Non traditional machining jagadeesha t, assistant professor, med, national institute of technology, calicut equipment. Ultrasonic machining is ultrasonic machining processes, as being developed and applied at ewi, consist of the. It also includes micronanofinishing processes viz, abrasive flow finishing, magnetic abrasive finishing, etc. Most grinding processes involve a work tool making direct contact with a work piece in order to gouge material away. An experimental study on ultrasonic machining of pure titanium using designed experiments in the present research work, the effect of several process parameters on the machining characteristics of pure titanium astm gradei has been reported. Ultrasonic machining from the technology data exchange linked to trusted tde listed vendors. Ultrasonic machining is a nontraditional machining process. This paper did a comprehensive analysis on ultrasonic machining mechanism in theory. External and internal cylindrical grinding of advanced materials for accurate geometries and optimum surface qualities. Ultrasonic enhancement of an electrochemical machining. Ultrasonic technology poised for advance into general machining.
Ultrasonic machining introduction ultrasonic machining is a nontraditionalmechanical means of uniform stock materialremoval processit is applicable to both conductive andnonconductive materials. Ultrasonic machining is a method of grinding that uses an abrasive liquid rather than direct tool contact. Parametric optimization of ptfe using ultrasonic machining. Slurry of abrasive and water vibration frequency f 19 25 khz amplitude, a 10 50. In this study, a novel chemicalassisted ultrasonic machining cusm method is introduced to overcome former disadvantages.
Given this, nontraditional machining is widely utilized in responding to modern industrial problems. In micro usm workpiece which is placed on the workpiece table vibrates at ultrasonic frequency 40 khz. 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. Ultrasonic machining offers an effective alternative for ultra precision machining of hard and brittle materials due to its unique characteristics. 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. Download as pptx, pdf, txt or read online from scribd. Ultrasonic machining, water jet machining, abrasive water jet machining. Ultrasonic machining is a nonconventional machining process. The method of making contact of metal with the enchant is masking.
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. Nontraditional machining processes flashcards quizlet. The process is more effective on materials that have hardness more than rc 40, but it is used on almost all including metallic and. That machining makes the plane compelling in ways that have led other countries to take up some of the cost. Extremely hard and brittle materials are difficult to machine by traditional machining processes such as turning, drilling, shaping and milling. History the roots of ultrasonic technology can be traced back to research on the piezoelectric effect conducted by pierre curie around 1880. Introduction, history of machining, traditional machining processes, nontraditional machining processes, hybrid machining processes. Although the impact pressure at the machining points is high owing to the ultrasonic oscillation of a high frequency and the small sizes of grains, the machining load is small enough to prevent the generation of large cracks in brittle materials. Advanced casting processes metal mould casting continuous casting squeeze casting vacuum mould casting evaporative pattern casting ceramic shell casting 6 3. Introduction in the vast and complex field of electrotechnologies, electrochemical machining technique ecm represents a relatively new and important method of. Lathe tools may benefit from deliberatelyinduced vibrations to prevent chatter which compromises the surface finish of the finished component.
Here is a look at a highvalue, highly engineered machining process for the joint strike fighter aircraft. During the warranty period, the manufacturer will, at its option, as the exclusive remedy. What are the major nontraditional machining processes. Micro ultrasonic machining micro usm, is one of the efficient material removal processes especially suitable for the micromachining of hard and brittle materials. Part 2 deals with thermal machining processes for example, electric discharge machining, laser beam machining, electron beam machining, etc. Mar 19, 2020 ultrasonic machining is a method of grinding that uses an abrasive liquid rather than direct tool contact. The part of the workpiece whose material is to be removed, is brought into the contact of chemical called enchant. 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. Ultrasonic machining is a contemporary manufacturing method usually employed for processing materials with higher hardnessbrittleness such as quartz, semiconductor materials, ceramics etc. Rotary ultrasonic machining of hardtomachine materials by nikhil churi b. Oct 22, 2008 lecture series on manufacturing processes ii by prof. Combining ultrasonic and conventional machining operations. However, despite the above benefits, ultrasonic machining has a low material removal rate and gives low surface quality.
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