Ultrasonic machining process for micro manufacturing processes

Ultrasonic machining process

1. ULTRASONIC
MACHINING
PROCESS
USM.

2. .
.
Ultrasonic
Waves of High
Frequency

3. Sound
.INFRA SONIC
WAVES
ULTRA SONIC
WAVES
AUDIBLE
WAVES

4. SUITABLE

5. PRINCIPLE

6. .

7. .
.
Ultrasonic
Generator
Used to convert the current from low
frequency to high frequency

8. Abrasive Slurry

9. .
.
Transducer
Used to convert
Electrical energy
into Mechanical
Vibrations

10. .
.
Tool Holder
Made up of Titanium alloy , Monel,
Aluminium, Stainless steel

11. .
.
Tool
Material
Low Carbon Material
and Stainless steel
Thetoolisbrazed,
solderedorFastened
mechanicallytothe
transducerthrougha
toolholder

12. Working of USM

13. .
Transducer
convertthehigh
frequency
electricalenergy
intoMechanical
Vibrations
Oscillatorconvertthe
Lowfrequencyelectrical
energyintohigh
frequency electrical
energy
20 –30 HZ
Vibrations are
transferred to
tool material
Abrasive Slurry
Passed
Between the
vibrating tool
and work piece
The
refrigeration
system used
to cool the
abrasive
slurry to 5 –
6 Degree
celcius

14. COMPARISON

15. TRANSDUCER

16. TYPES OF TRANSDUCER

17. MAGNETOSTRICTIVE TRANSDUCER
.
Change in length is independent of
the direction of the magnetic field
But depend only on the
magnitude of the field and
Nature of the material

18. MAGNETOSTRICTIVE TRANSDUCER

19. MAGNETOSTRICTIVE TRANSDUCER
LT battery used to
heat the filament
So electrons are
produced
Those electrons
are accelerated
by HT Battery
So AC current
Produced in the
circuit

20. So Rod start
to vibrate
due to
magnetostric
tiveeffect
This vibrations rod
create Ultrasonic
Waves , which sent out
MAGNETOSTRICTIVE TRANSDUCER

21. MAGNETOSTRICTIVE TRANSDUCER
The Longitudinal Extension
and contraction of the Rod AB
produce an EMF in the coil L2

22. Resonance
Frequency of the
oscillatory circuit
Frequency of Vibrating
Rod
=
Resonance will occur when
At resonance , the rod vibrates vigorously and ultrasonic
waves are produced at high frequencies

23. Advantages –
Magnetostrictive Transducer

24. Disadvantages –
Magnetostrictive Transducer

25. PIEZOELECTRIC TRANSDUCER
Itsmoreefficientthanmagnetostrictivetransducer
ThemodernUSMareofthistype.

26. PIEZOELECTRIC
effect
crystal

27. Definition -Piezoelectric
•Piezoelectrictransducersareatypeofelectro
acoustictransducerthatconverttheelectrical
chargesproducedbysomeformsofsolid
materialsintoenergy.
•Theword"piezoelectric"literallymeans
electricitycausedbypressure.

28. Circuit

29. Arrangement of the circuit

30. Working
LT battery used to
heat the filament
So electrons are
produced
Those electrons are
accelerated by HT Battery
So AC current
Produced in the
circuit
This AC current Passes
through L1 and L2 and
its transferred to
Secondary circuit
This AC current passed to the plates A and B and it make the
Crystal to vibrate due to the principle of inverse piezoelectric
effect. The vibrations of crystal creates Ultrasonic waves

31. Resonance

32. Advantages–Piezoelectric transducer
Disadvantages–Piezoelectric transducer
1.Piezoelectric quartz is high cost
2.Cutting and shaping of crystal is very complex.

33. MRR
MRR Per unit time

34. Wear Ratio

35. Factors considered for MRR
in USM

36. Grain size of Abrasives

37. Abrasive material
It Depend on
1.The type of material to be machined
2. Requirement of Surface finish
For Machining -Tungsten Carbide
-Die Steel
Boron Carbide
Silicon Carbide
Abrasives
For Machining -Glass
-Ceramics
Aluminiumoxide

38. Concentration of Slurry
Abrasive Slurry = Abrasive Particles + Water

39. Amplitude of Vibration
MRR increase with the increase of Amplitude of Vibration

40. Frequency
MRR increases with the increase of Ultrasonic wave
Frequency

41. Process Parameters

42. Tool Material
Lengthy tool causes overstresses
So tool should be short and rigid
Process Parameters

43. Process Parameters
Wear Ratio
1.5 : 1 For Tungsten Carbide Work Pieces
100 : 1 For Glass Work Pieces
50 : 1 For Quartz Work Pieces
75 : 1 For Ceramics
1 : 1 For Hardened tool steel Work Pieces

44. Abrasive Material and
Cutting Power
Process Parameters

45. Advantages of USM

46. Disadvantages of USM

47. Applications