Find manufacturing technology and production articles for engineering students and professionals. Ultrasonic technology poised for advance into general 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. The garant machining handbook summarises accumulated knowledge on the subjects of machining and clamping, from a to z. If you liked it then please share it or if you want to ask anything then please hit comment button. Ultrasonic machining national institute of technology. Today robots are available that can feed various machines, such as a milling machine, wire edm, and a ram edm. Hydrodynamic cavitation machining hcm, and ultrasonic cavitation machining ucm, they will be. Lithography based micro machining technology uses silicon as material to. Which of the following statement is wrong about ultrasonic machining. Principle of ultrasonic machining in the machining process, the tool, at some. It is employed to machine hard and brittle materials both electrically conductive and.
Singh, balbir singh modern machining processes presents unconventional machining methods which are gradually commercial acceptance. Navy during world war ii to detect enemy submarines. Under his supervision, reliable edm has become the largest wire edm job shop in the north america. It is also known as ultrasonic impact grinding is an operation that involves a vibrating tool fluctuating the ultrasonic frequencies in order to remove the material from the work piece. The basic usm process involves a tool made of a ductile and tough material vibrating with a low amplitude and very high frequency and a continuous flow of an abrasive slurry in the small gap between the tool and the work piece. 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. Hypersound, sometimes called praetersound or microsound, is sound waves of frequencies. A practical guide woodhead publishing in mechanical engineering paulo davim, j on. 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. It was all about high speed machining hsm seminar and ppt with pdf report. 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. The term sonic is applied to ultrasound waves of very high amplitudes. Electrochemical and chemical metal removal processes electrochemical machining electrochemical grinding electrochemical deburring electrochemical honing chemical machining chapter 4.
Rotary ultrasonic machining of hardtomachine materials by nikhil churi b. Ultrasonic testing ut is a family of nondestructive testing techniques based on the propagation of ultrasonic waves in the object or material tested. In most common ut applications, very short ultrasonic pulsewaves with center frequencies ranging from 0. In my opinion, the application of ultrasonic machining is the only method that completely satisfies logic, from a technical viewpoint, and explains all noted phenomena. The introduction of abrasives to the fluid jet enhances the. Paul,department of mechanical engineering, iit kharagpur. 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. Non tradition machining national institute of technology. Ultrasonic machining from the technology data exchange linked to trusted tde listed vendors. The book should be useful to students of production and mechanical engineering, as well as practising engineers. In rum, the basic material removal phenomenon of ultrasonic machining usm and conventional diamond grinding.
Ultrasonic machining machining handbooks asm international. Ultrasonic assisted machining uam should not be confused w ith ult rasonic machining usm which is a wellestablished technique for machining hard and brittle materials with a history. Ultrasonic machining free download as powerpoint presentation. Ultrasonic machining, or strictly speaking the ultrasonic vibration machining, is a subtraction. Ultrasonics, vibrations of frequencies greater than the upper limit of the audible range for humansthat is, greater than about 20 kilohertz. It also depends on the size of grains of the abrasive slurry, the rigidity and the viscosity as well.
This chapter presents usm and rotary ultrasonic machining rum, including definitions, machine elements, input variables and their effects, applications, and advantages and disadvantages. Ultrasonic machining usm and waterjet machining wjm are typical examples of single action, mechanical non traditional machining processes. 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. Ultrasonic machining is a relatively old machining technique whose basis was laid way back in 1927 and was patented by l.
In this study, a novel chemicalassisted ultrasonic machining cusm method is introduced to overcome former disadvantages. Machining is any of various processes in which a piece of raw material is cut into a desired final shape and size by a controlled materialremoval process. Ultrasonic machining is a mechanical type nontraditional machining process. The ultrasonic machining center is also a fully capable conventional machining center. Rotary ultrasonic machining rum is a nontraditional hybrid process, which combines the mechanisms of diamond grinding and usm 11. 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. History the roots of ultrasonic technology can be traced back to research on. Elsevier journal of materials processing technology 48 1995 771777 journal of materials processing technology plastic flow in rotary ultrasonic machining of ceramics z.
Discuss how modern machine technology affects the workforce. Rotary ultrasonic machining rum is a mechanical type of nontraditional hybrid machining process that has been utilized potentially to machine a wide range of latest and difficultto machine materials, including ductile, hard and brittle, ceramics, composites, etc. Chemicalassisted ultrasonic machining of glass sciencedirect. Features such as smooth shiny surfaces, smalldiameter deep holes in a part, threaded section, and threaded holes all require further manufacturing operations. Haselkornb adepartment of mechanical and industrial engineering, university of illinois at urbanachampaign, 1206 west green street, urbana, il 61801, usa btechnical center, caterpillar inc. The tool travels vertically or orthogonal to the surface of the part at amplitudes of 0. A new nontraditional machining method using cavitation process. History the roots of ultrasonic technology can be traced back to research on the piezoelectric effect conducted by pierre curie around 1880. Ultrasonic machining centers take your machining capabilities to the next level, along with your bottom line, with optisonic. All aspects of mechanical, electrochemical and thermal processes are comprehensively covered. To learn about various unconventional machining processes, the various process parameters and their influence on performance and their applications. This paper presents a new method in machining of materials using cavitation process. Ultrasonic machining is nontraditional machining process which is used to machine brittle and hard material. Unlike other nontraditional processes such as laser beam, and electrical discharge machining, etc.
The process involves an abrasive slurry that runs between the tool and the work piece. However, despite the above benefits, ultrasonic machining has a low material removal rate and gives low surface quality. Frequency values of up to 1ghz 1 billion cycles per second have been used in the ultrasonic industry. Ultrasonic transducers are key components in sensors for distance, flow and level measurement as well as in power, biomedical and other applications of ultrasound. Ultrasonic machining usm is a mechanical material removal process used to erode holes and cavities in hard or. The authors declared no potential conflicts of interest with respect to the research, authorship, andor publication of this article.
Machining a material removal process in which a sharp cutting tool is used to mechanically cut away material so that the desired part geometry remains most common application. Exercises 6 summary summary the edition addresses issues essential to modern manufacturing, ranging from traditional topics such as casting, forming, machining, and joining, to advanced topics such as the fabrication of nanomaterials. 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. On this channel you can get education and knowledge for general issues and topics. Rotary ultrasonic machining rum is a nontraditional machining process that combines. Ultrasonic assisted machining is performed by applying a certain vibration to the cutting tool or to the workpiece to improve the tool life and surface properties in finishing process applications. Mechanical, electrical, thermal, and chemical material removal procedures are also summarized. Particularly suited for very hard andorbrittle materials such asgraphite, glass, carbide, and ceramics. The time spent on ultrasonic machine entirely depends on the frequency of the vibrating tool. Plastic flow in rotary ultrasonic machining of ceramics. Unit ii mechanical energy based processes 10 abrasive jet machining water jet machining abrasive water jet machining ultrasonic machining. It also provides schematic representations of the components used in rotary usm and ultrasonic impact grinding. The volume, featuring 1,300 illustrations and 620 tables, includes process capabilities, machines, cutting parameters plus variables, and applications of traditional machining processes such as turning, drilling, and milling.
The main reason why this machining process is used in the manufacturing area is because it evolves less heat in the process. Studies on some aspects of ultra sonic machining usm. His introduction to the machine tool trade goes back to 1949, at a new york city machine shop. A new nontraditional machining method using cavitation.
The most significant detail of the drilled holes and cores studied by petrie was that the groove was. Table of contents foreword preface list of symbols chapter 1. Pdf me6004 unconventional machining processes ump books. There are other operations too that fall in miscellaneous categories such as boring, sawing, shaping, and broaching. An introduction to machining technology learning objectives after studying this chapter, students will be able to. This machining process comes into existence in 1950 for finishing edm surface. 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. Give a brief explanation of the evolution of machine tools. Ultrasonic machining read books, audiobooks, and more. Today we will learn about ultrasonic machining, principle, working, equipments, application, advantages and disadvantages with its diagram. How to build a hinged hoophouse for a raised bed garden duration.
An analysis of material removal in ultrasonic machining due to. Advanced processes include electrical and chemical means of material removal, as well as the use of abrasive jets, water. The ultrasonic technology from dmg mori enables the economical machining of complex workpiece geometries in demanding hightech materials like e. Recent developments and research issues in microultrasonic. Ultrasonic machining usm is a nontraditional mechanical machining process and can be used in many applications. Mechanical, electrical, thermal, and chemical material removal procedures are. Modern machining process abebooks shop for books, art. Apr 15, 20 ultrasonic machining introduction ultrasonic machining is a nontraditionalmechanical means of uniform stock materialremoval processit is applicable to both conductive andnonconductive materials. Its the product of longtime experience and expert knowledge of garant machining specialists.
Mechanical processes ultrasonic machining abrasive jet machining water jet machining chapter 3. Machining and machine tools is an important subject with application in. To get the chemical effect, a low concentration of hydrofluoric acid was added to the abrasive slurry. Micro machining is defined as the ability to produce features with the dimensions from 1 m to 999 m or when the volume of the material removed is at the micro level. This article lists the major ultrasonic components that are similar to both rotary usm and ultrasonic impact grinding. The machining medium is solid grains suspended in an abrasive slurry in the former,while a fluid is employed in the wjm process. All aspects of mechanical, electrochemical and thermal processes are. Discover everything scribd has to offer, including books and audiobooks from major publishers. 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. He found that asymmetrical crystals such as quartz and rochelle salt potassium. Non traditional machining jagadeesha t, assistant professor, med, national institute of technology, calicut ultrasonic machining definition. Machining operations are classified into 3 principle processes and they are turning, drilling and milling.
Unconventional machining process need classification brief overview. He has worked many years in programming and operating edm equipment. Modeling and optimization of ultrasonic machining process. Advanced nontraditional machining processes 303 work. Machining is the broad term used to describe removal of material from a workpiece includes cutting, abrasive processes grinding, advanced machining processes electrical, chemical, thermal, hydrodynamic, lasers automation began when lathes were introduced in 1700s now have computer numerical control cnc machines. Match listi machining process with listii associated medium and select the correct answer using the codes. History one of the first applications for ultrasonic was sonar an acronym for sound navigation ranging.
The processes that have this common theme, controlled material removal, are today collectively known as subtractive manufacturing, in distinction from processes of controlled material addition, which are known as additive manufacturing. Then you can start reading kindle books on your smartphone, tablet, or computer no. Ultrasonic vibration is assumed to be stable or unchangeable during the process of rotary ultrasonic machining rum on brittle materials, neglecting the effects of different processing parameters. Usm offers a solution to the expanding need for machining. Modeling and optimization of ultrasonic machining process using a novel evolutionary algorithm. Particularly suited for very hard andorbrittle materials such asgraphite, glass, carbide, and. Ultrasonic machining is of particular interest for the cutting of nonconductive, brittle workpiece materials such as engineering ceramics. Carl sommer, owner and president of reliable edm corporation in houston, texas, the largest wire edm job shop in the southwest, has a wide and varied background in the machine tool trade. B it cuts materials at very slow speeds c it removes large amount of material d it produces good surface finish. Ultrasonic machining introduction ultrasonic machining is a nontraditionalmechanical means of uniform stock materialremoval processit is applicable to both conductive andnonconductive materials. A it is best suited for machining hard and brittle materials. Oct 22, 2008 lecture series on manufacturing processes ii by prof.
Experience unprecedented machining efficiency with high performance ultrasonic milling, grinding, core drilling and lightweighting of optical glasses and ceramics. Ultrasonic machining usm is one of the nonconventional techniques for machining of hard and brittle materials like glass, ceramics, and ceramic matrix. The gardening channel with james prigioni recommended for you. A lot of helpful information, application tips and tricks can be found on more than pages compact, wellarranged and uptodate. Download link is provided and students can download the anna university me6004 unconventional machining processes ump syllabus question bank lecture notes syllabus part a 2 marks with answers part b 16 marks question bank with answer, all the materials are listed below for the students to make use of it and score good maximum marks with our study materials. A practical guide woodhead publishing in mechanical engineering. Ultrasonic machining is changing the manufacturing industries with its superlative performance. Non traditional machining jagadeesha t, assistant professor, med, national institute of technology, calicut equipment. A specific machine tool is required for taking care of each machining operation.
The ultrasonic machining usm process consists of two methods, namely, ultrasonic impact grinding and rotary usm. 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. Micro machining is the most basic technology for the production of such miniature parts and components. Part one provides an overview of materials and design of ultrasonic.
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