Ultrasonic Machining (USM)

Dr. Venkaiah N

“Everything in your life is a reflection of a choice you have made. If

you want a different result, make different choices.”
- Anonymous
 Learning Outcomes
At the end of this lecture, student should be able to

v  Explain working of USM

v  Explain functions of the components of USM process

v  Explain mechanism of material removal

v  Explain the effect of process parameters on responses

v  List and explain the USM variants

v  List merits, demerits and applications of USM

 USM  –  Working  
•  Grit  loaded  slurry  is  circulated  between  the  tool  and  the  workpiece  
•  Vibra=ons   of   small   amplitude   (10–20   μm)   and   high   frequency   (20–40  
kHz)  are  given  to  the  tool.  
•  Hard   abrasives   in   the   slurry   are   accelerated   towards   the   workpiece  
surface  by  the  oscilla=ng  ac=on  of  the  tool.  
•  Tool   is   fed   toward  
and   held   against  
the   workpiece   by  
means   of   a   sta=c  
pressure   that   has  
to   overcome   the  
cuMng   resistance  
at   the   interface   of  
t h e   t o o l   a n d  
workpiece.  
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 USM  –  Working  …  
•  CuMng   is   performed   by   the   abrading   ac=on   of   the   abrasive  
par=cles  
•  Replica  of  the  tool  shape  will  be  obtained  on  the  workpiece  
•  Material  is  removal  in  the  form  of  fine  grains.  
•  Shape   and   dimensional   accuracy   are   directly   dependent   on  
the  tool.    
•  Which  materials  can  be  machined?  à  BriTle  materials    (glass,  
ceramics  and  diamond)  
•  Intricate  shapes  can  be  cut  easily  
•  No   change   in   the   chemical,   physical   or   metallurgical  
proper=es  of  the  workpiece  
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USM  –  Video  

Glass Drilling by USM

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Block  Diagram  of  USM  

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 USM  Setup  
Main  elements:  
•  Magnetostrictor  
or   Piezoelectric  
transducer  

•  Concentrator  

•  Tool  

•  Slurry   feeding  
arrangement   7
 Magnetostrictor  
•  Has   a   high-­‐frequency  
winding  
•  Magnetostric=on   effect:  
Ferromagne=c   materials  
change   their   shape   or  
d i m e n s i o n s   d u r i n g  
magne=za=on.  
•  M a g n e t o s t r i c = v e  
materials   can   convert  
magne=c   energy   into  
kine=c   energy,   or   the  
reverse,   and   are   used   to  
b u i l d   a c t u a t o r s   a n d  
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sensors.  
 Mechanical  Amplifier  
•  The  elonga=on  obtained  at  the  resonance  
frequency  (fr)  using  a  magnetostrictor  of  
length l =  0.5  λ  is  usually  0.001  to  0.1  μm.  
•  This  is  too  small  for  prac=cal  machining  
applica=ons.    
•  Amplitude  is  increased  by  fiMng  an  
amplifier  (acous=c  horn)  into  the  output  
end  of  the  magnetostrictor.  
•  Larger  amplitudes,  typically  40  to  50  μm,  
are  found  to  be  suitable  for  prac=cal  
applica=ons.  
•  Depending  on  the  final  amplitude  required,  
the  amplitude  amplifica=on  can  be  
achieved  by  one  or  more  acous=c  horns.   9
 Tools  
•  Tool  =ps  must  have    
Ø  high  wear  resistance  
Ø  High  fa=gue  strength  
•  Copper   and   chromium   silver   steel   tools   à   for   machining  
glass  and  tungsten  carbide  
•  Silver   and   chromium   nickel   steel   à   for   machining   sintered  
carbides  
•  Tool  feed  mechanisms:  
–  Pneuma=c  
–  Periodic  switching  of  a  stepping  motor  or  solenoid  
–  Compact  spring-­‐loaded  system  
–  Counterweight  techniques.  
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 Abrasive  Slurry  
•  The   abrasive   slurry   is   con=nuously   fed  
into   the   machining   zone   to   ensure  
efficient   flushing   of   debris   and   keep  
the  machining  area  cool.  
•  Slurry   composi=on:   50   vol.   %   of   fine  
abrasive   grains   (of   Grit   No.   100-­‐800)  
and  50  vol.  %  of  water.  
•  Abrasives:   Boron   carbide   (B 4 C),  
Aluminum   oxide   (Al2O3)   or   Silicon  
carbide  (SiC)  
•  The  slurry  is  pumped  at  a  rate  of  25  L/min.  
•  As   machining   progresses,   the   slurry   becomes   less   effec=ve   as   the   par=cles  
wear  and  break  down.  
•  The  expected  life  ranges  from  150  to  200  h  of  ultrasonic  exposure  
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 Mechanism  of  Material  Removal  

v  Material  removal  mechanism  of  USM  involves  three  dis=nct  ac=ons:  
1.  Mechanical  abrasion  by  localized  direct  hammering  of  the  abrasive  grains  
stuck  between  the  vibra=ng  tool  and  adjacent  work  surface.  
2.  The   micro-­‐chipping   by   free   impacts   of   par=cles   that   fly   across   the  
machining  gap  and  strike  the  workpiece  at  random  loca=ons.  
3.  The  work  surface  erosion  by  cavita=on  in  the  slurry  stream.  
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Mechanism  of  Material  Removal  …  
•  Dominant  mechanism    à  direct  hammering  

•  Contribu=on  of  cavita=on  effect  à  <  5  %  of  the  total  material  
removed  

•  Sok   and   elas=c   work   materials   like   mild   steel   à   plas=cally  

deformed  first  and  are  later  removed  at  a  lower  rate  

•  Hard   and   briTle   materials   such   as   glass   à   machining   rate   is  

high  and  the  role  played  by  free  impact  can  also  be  no=ced  

•  Porous  materials  such  as  graphite  à  Erosion   13

Chipping  Rate  
 MRR  
•  Factors  affec=ng  MRR:  
Ø  Amplitude  &  Frequency  of  tool  vibra=on,    
Ø  Sta=c  pressure,    
Ø  Machined  area,    
Ø  Abrasive  material  and    
Ø  Workpiece  material  

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 MRR  …  
Amplitude  &  Frequency  of  tool  vibra7on:  
•  Amplitude   of   the   tool   oscilla=on   has   the   greatest   effect   of   all  
the  process  variables.  
•  Higher   tool   vibra=on   amplitude   à   higher   kine=c   energy   à  
enhanced  mechanical  chipping  ac=on  à  higher  MRR  
•  A  very  high  vibra=on  amplitude  may  lead  to  the  occurrence  
of   splashing,   which   causes   a   reduc=on   of   the   number   of  
ac=ve  abrasive  grains  and  results  in  a  decrease  in  the  MRR.  
•  Higher   the   vibra=on   frequency   à   lesser   the   chipping   =me  
for  each  grain  à  lower  chipping  ac=on  à  lower  the  MRR  
•  Higher  the  feed  force  à  greater  the  chipping  forces  by  each  
grain  à  higher  the  MRR  
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 MRR  …  
2.  Abrasives  
•  Both   the   grain   size   and   the   vibra=on   amplitude   have   a   similar  
effect  on  the  removal  rate.  
•  MRR   rises   un=l   the   grain   sizes   reach   the   vibra=on   amplitude,   at  
that  stage,  the  MRR  decreases  
•  Grain   size   >   vibra=on   amplitude   à   difficulty   of   abrasive  
renewal  
•  B4C   à   higher   hardness   à   higher   removal   rates   than   silicon  
carbide  (SiC)  when  machining  glass  

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 MRR  …  
•  Carrying  liquid:  
Ø  Water  is  commonly  used    
Ø  Benzene,  glycerol,  and  oils  are  other  alterna=ves  
•  Low   slurry   viscosity   à   beTer   flow   of   slurry   à   enhanced  
MRR  
•  Volumetric  concentra=on  of  abrasives:  30  to  35  %  
•  A   change   of   concentra=on   occurs   during   machining   as   a  
result  of  the  abrasive  dust  seTling.  
•  The   actual   concentra=on   should,   therefore,   be   checked   at  
certain  =me  intervals.  

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 MRR  …  
3.  Workpiece  Impact  Hardness  
•  MRR  is  affected  by  the  ra=o  of  tool  hardness  to  workpiece  hardness.  
•  Higher  the  ra=o  à  Lower  will  be  MRR  (If  tool  hardness  increases,  abrasives  
loose  their  sharpness  and  therefore,  MRR  decreases)  
•  Sok  and  tough  tool  materials  are  used  
4.  Tool  Shape:  Larger  tool  area  à  inadequate  distribu=on  of  abrasive  slurry  
over  the  en=re  area  à  lower  machining  rate  
5.  Sta7c  Pressure:    
•  Lower   than   the   op=mum   à   lower   force   on   the   grain   to   press   into   work  
material  à  low  MRR  
6.  Hole  depth:  Deeper  the  hole,  lower  will  be  the  MRR  
•  Reason:   deeper   the   tool   reaches,   the   more   difficult   and   slower   is   the  
exchange  of  abrasives  from  underneath  the  tool.  
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MRR  …  

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 Surface  Quality  
•  Rela=onship  among  grit  number,  grit  size  and  roughness  

 
•  Larger  the  grit  number  (smaller  grain  size),  the  surface  will  be  
smooth.  
•  Larger  the  grit  size,  faster  the  cuMng  rate  but  surface  finish  is  
poor.  
•  However,  other  factors  such  as  tool  surface,  amplitude  of  tool  
vibra=on,  and  material  being  machined  also  affect  the  surface  
finish.   21  
 Surface  Quality  …  
•  Higher   amplitude   à   deeper   grain   penetra=ons   into   the  
workpiece  surface  à  deeper  craters  à  rough  surface  
 
•  Sidewalls   are   scratched   by   abrasive   grains   à   roughness   of  
sidewalls  is  larger  than  those  on  the  boTom  

•  Sta=c  pressure  has  a  liTle  effect  on  the  surface  finish  

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 Accuracy  
Accuracy  is  measured  using  
–  Oversize,    
–  Conicity,  and  
–  Roundness  

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 Oversize  (Overcut)  
•  Overcut   =   Hole   diameter   (measured   at   the   top   surface)   –   tool  
diameter  
•  Side   gap   between   tool   and   hole   is   necessary   to   enable  
abrasive  flow.    
•  Grain  size  of  the  abrasives  affects  the  overcut  produced  
•  Overcut  >  3  =mes  mean  grain  size  
•  Magnitude   of   overcut   also   depends   on   many   other   process  
parameters   (type   of   workpiece   material   and   the   method   of  
tool  feed).  
•  Accuracy  levels  are  limited  to  +  50  μm  

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 Conicity  (non-­‐parallel  sides)  
•  Cumula=ve   abrasion   effect   of   fresh   and   sharp   grains   à   greater  
overcut  at  the  entry  side  than  at  the  exit  
•  Example:    
Ø  While  drilling  a  hole  of  20  mm  size,  and  a  depth  of  10  mm  in  
graphite  à  Conicity  =  ~  0.2o  
•  The  conicity  may  be  reduced  by  
–  Use  of  wear-­‐resistant  tool  materials  
–  Use  of  an  undersized  tool  in  the  first  cut  and  a  final  tool  of  the  
required  size,  which  will  cut  faster  and  reduce  the  conicity  
–  Use  of  tools  having  nega=vely  tapered  walls  

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 Roundness  Error  
•  Roundness  error  arises  by  the  lateral  vibra=ons  of  the  tool  

•  Such  vibra=ons  are  due  to  out  of  perpendicularity  of  tool  face  
and  center  line  

•  Typical  values:  

-­‐  40  -­‐  140  μm  for  glass  and    

-­‐  20-­‐60  μm  for  graphite  

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 USM  Variants  
1.  Rotary Ultrasonic Machining (RUM)

2.  Ultrasonic  sinking  and  contour  machining  

3.  Ultrasonic  Polishing  

4.  Micro-­‐Ultrasonic  Machining  (MUSM)  

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 Rotary  Ultrasonic  Machining  (RUM)  
•  Tool  is  rotated  similar  to  conven=onal  
drilling  
•  Deep  holes  require  longer  =me  as  the  
rate   of   machining   decreases   with   the  
depth   of   penetra=on.   This   is   due   to  
the   difficulty   in   maintaining   a  
con=nuous   supply   of   new   slurry   at   the  
tool  face.  
•  Rota=on  of  tool  enables:  
Ø High  removal  rates,  lower  tool  pressures  for  delicate  parts  
Ø Improved  deep  hole  drilling  
•  Depth-­‐to-­‐diameter  ra=o  of  2.5  is  achievable  by  RUM   28  
 Ultrasonic  sinking  and  contour  machining  

•  Drawbacks  with  ultrasonic  sinking:    

Ø  If   depth   >   5   to   7   mm,   renewal   of   abrasives   at   the   interface   becomes  
difficult  à  material  removal  is  impossible  
Ø  Manufacturing  of  such  a  tool  is  generally  complex  and  costly.  
•  Contouring  USM  -­‐  simple  tools  that  are  moved  along  the  contour  required  
Ultrasonic  sinking  and  contour  machining  

(contour  USM)  
Silicon  nitride  turbine  blades  
(sinking)  

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 Ultrasonic  Polishing  
•  Fine   abrasive   par=cles   abrade   the   high   spots   of   the   workpiece  
surface  
•  BriTle  tool  material  (graphite  or  glass)  is  used  
•  Removes  12  μm  of  material  or  less  
•  Surface  roughness:  0.3  μm  

Fig. Ultrasonic polishing done for 2 min to remove the machining marks left by
a CNC engraving operation.
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 Micro-­‐Ultrasonic  Machining  (MUSM)  
•  U=lizes  workpiece  vibra=on  
•  Vibra=ng  the  workpiece  allows  flexibility  in  tool  system  design  
as  it  does  not  include  the  set  of  transducer,  horn,  and  cone.  
•  In   addi=on,   the   complete   system   is   much   more   simple   and  
compact  than  conven=onal  USM.  
•  Micro-­‐holes   of   5   μm   diameter   on   quartz,   glass,   and   silicon  
have  been  produced  using  tungsten  carbide  (WC)  alloy  micro-­‐
tools  
•  Can  machine  3-­‐D  shapes  

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 MUSM - Concept

Micro-­‐ultrasonic  machined  cavity  

Micro-­‐ultrasonic  machining   33  
 Advantages  of  USM  
•  CuMng   forces   are   low   à   induced   stresses   are   too   less   à  
hence  no  structural  changes  

•  No   direct   contact   of   tool   with   workpiece   à   wet   cuMng  

process  à  no  thermal  changes  

•  Surfaces  produced  are  free  from  burrs  and  distor=ons  

•  Good  surface  finish  

•  Environmental  friendly  process  

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 Limita=ons  of  USM  
•  Sok  materials  (lead  and  plas=cs)  tend  to  absorb  the  abrasive  
par=cles   rather   than   to   chip   under   their   impact   à   Not  
suitable  by  the  USM  
•  Power  consump=on  is  quite  high  
•  Tool  wear  rate  is  high  
•  Larger  areas  of  machining  and  higher  depths  are  not  possible  
•  If   the   axes   of   the   tool   and   horn,   which   are   brazed   together,  
are   not   properly   aligned   with   the   transducer   axis   à   strong  
lateral  vibra=ons  à  tapered  holes  
•  Sharp   corners   of   the   tool   get   rounded   off   à   frequent   tool  
replacements  for  producing  accurate  blind  holes  
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 USM  -­‐  Applica=ons  
•  Suitable   for   machining   hard   and   briTle   materials   such   as  
glass,  ceramics  and  carbides.  
•  Also  successful  on  stainless  steel  and  =tanium  
•  Coining  opera=ons  -­‐  paTern  on  tool  is  imparted  to  a  flat  work  
surface  
•  Par=ng  and  machining  of  precious  stones  including  diamond  
•  Drilling   small   holes   in   helicopter   power   transmission   shaks  
and  gears.  
•  Used  for  punch  and  die  making  

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