What is Ultrasonic Machining - Ultrasonic Machining Principle, Advantages and Application

What is Ultrasonic Machining – Ultrasonic Machining Principle, Advantages and Application | CNCLATHING

2020.12.4

With a number of manufacturing methods, manufacturers often want to find the best way for the specific project. The material to be processed will affect the selection of the machining process. In this article, let’s take an overview of the ultrasonic machining process, covering its working principle, tools, advantages, disadvantages, and application.

What is Ultrasonic Machining?

Ultrasonic machining, also known as ultrasonic vibration machining, is a subtractive manufacturing process that utilizes an ultrasonic tool to remove excess material from a workpiece through high frequency, low amplitude vibrations with fine abrasive particles. The tool is usually made from materials such as soft steels and nickel. Ultrasonic machining is usually used to cut non-conductive, brittle materials because it does not produce thermal damage or significant levels of residual stress on the part, which is critical for the machining of brittle materials.

Working Principle of Ultrasonic Machining - How Does Ultrasonic Machining Work?

In ultrasonic machining, the tool moves vertically or orthogonal to the surface of the part and fluctuate at the ultrasonic frequencies, the vibrations generated by the tool will project micro-sized abrasive particles to the part at a high speed, the particles mix with water or other liquids to form a slurry, which flowing between tool and workpiece, helps to grind away material from the surface of the piece. During the operation, the tool and the ultrasonic machining part never interact with each other. The particles used in the abrasive fluid are usually boron carbide or silicon carbide as they are rigid than others.

Ultrasonic Machining Advantages and Disadvantages

There are a ton of subtractive production methods, such as CNC turning, milling, and more. Unlike other manufacturing techniques, the ultrasonic machining process has unique benefits. It is capable of removing materials from almost all types of materials, whether strong or brittle parts, such as ceramic. It also does not need to change the temperature. Despite all this, ultrasonic machining also has some shortcomings.

Advantages of Ultrasonic Machining

– Suitable for almost all types of materials

– Do not need heating or cooling during the machining process

– Capable to offer a higher tolerance than many other processes

– Idea choice for ceramic matrix composites, glass, quartz, diamonds, PCD, etc.

– Evolves less heat

– No distortion of the worked material

– No burrs are created in the process

– Good surface finish

Disadvantages of Ultrasonic Machining

– The rate of material removal is lower than most other machining techniques

– Not suitable for the mass production run

– Higher requirements for operator skills

– Unnecessary large particles may cause defects

– Drilling deep holes in parts are difficult

– Can only be used on materials with a hardness value of at least 45 HRC

Application of Ultrasonic Machining - What is Ultrasonic Machining Used for

There is no heat generation in the ultrasonic machining process, so the workpiece will not deform and the physical properties of the part will remain uniform. It is very useful for materials that are brittle and sensitive.

– Machining ceramics, carbides, glass, precious stones, and hardened steels

– Create microelectromechanical system components such as micro-structured glass wafers

– Manufacture parts with high precision and tolerance

– Grinding the brittle materials

– Slicing and broaching hard materials

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