It is a mechanical nontraditional machining process by which workpiece material is removed and an exact shape is imparted to the workpiece surface via the cutting action of an abrasive slurry that is driven by tool vibrating at high frequency in line with its longitudinal axis. 3. 3.The vibrating frequency used for the tool in Ultrasonic machining is of the order of. USM can machine these materials although with some difficulty. a. Any electrical conductor can be machined by this method. If you continue browsing the site, you agree to the use of cookies on this website. A uniform spark gap of 0.5 mm on both sides of the wire is maintained during cutting operation. d) 45,000 oscillations per second . • Under such conditions, the removal of abrasives at the interface becomes difficult and hence the material removal process is impossible. See our Privacy Policy and User Agreement for details. Ultrasonic machining (USM) is the removal of material by the abrading action of grit-loaded liquid slurry circulating between the workpiece and a tool vibrating perpendicular to the workpiece at a frequency above the audible range. The shaped tool under the actions of mechanical vibration causes the abrasive particles dipped in slurry to be hammered on the stationary workpiece. Ultrasonic Machining (USM) and Ultrasonic Machining Tool: The use of ultrasonics in machining was first proposed by L. Balamuth in 1945. c. Direct contact machining A. Ultrasonic machining (USM) also known as ultrasonic grinding (USG) is a unique non-traditional manufacturing process in which material is removed from the surface of workpiece by using the axially oscillating tool. d. none of these Machining and Thermal aspects (MGU S8 ME), No public clipboards found for this slide. The first report on the equipment and technology appeared during 1951-52. In ultrasonic machining, a liquid filled with abrasive material flows through over the work piece, and the work tool vibrates against the abrasives. Slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. b. In ultrasonic machining processes, a formed tool made of ductile and tough material, having the shape of the cavity to be machined is made to vibrate against the workpiece surface, and between the two, continuous flow of slurry of abrasive particles is maintained. Clipping is a handy way to collect important slides you want to go back to later. Ultrasonic machining is a process of manufacturing that removes material from the surface through high frequency, low amplitude vibrations of a tool against the material surface, presence of fine abrasive particles. i. Which of the following is not true in case of Electrical discharge machining (EDM)? iii. a. Burr free Most grinding processes involve a work tool making direct contact with a work piece in order to gouge material away. a. By 1954, the machine tools, using the ultrasonic principle, had been designed and constructed. An ultrasonic tool essentially creates many small vibrations that, over time, remove material from the workpiece with which it’s used. Which the following is true for Electrical Discharge machining (EDM)? 5 to 5 1. a. vacuum chamber Ultrasonic Machining is mainly used to machine hard and brittle materials with low ductility. 7. • Moreover, manufacturing of such a tool is generally complex and costly. (Ans:a). c. 10,000°C d. 0005, 0.005 C. Maintaining an electrolyte between the work and tool in a very small gap between the two. a) 10,000 oscillations per second. In ultrasonic machining, the metal is removed by. PRINCIPLE OF ULTRASONIC MACHINING •In the process of Ultrasonic Machining, material is removed by micro-chipping or erosion with abrasive particles. 6. b. c. Mechanical erosion in work piece takes place A titanium sheet of 5 mm thickness is cut by wire-cut EDM process using a wire of 1 mm diameter. 5.6 Ultrasonic Machining 5.7 Chemical Machining Processes 5.8 Electrochemical Machining 5.9 Laser Beam Machining 5.10 Plasma Arc Machining 5.11 Summary 5.12 Answers to SAQs 5.1 INTRODUCTION Modern machining methods are also named as non-conventional machining methods. Now customize the name of a clipboard to store your clips. abrasive slurry to remove the material from the workpiece. b. dielectric medium 6,000°C c) abrasive action. The abrasive particles, as they indent, the work material, would remove the same, particularly if the work material is brittle, due to crack initiation, propagation and brittle fracture of the material. In this machining material is removed by indentation of abrasive particle on work-piece. Looks like you’ve clipped this slide to already. The unit removal (UR) which is defined as the part of a work piece removed during one cycle of removal action, can be realized in MUSM when the submicron particles are available for use as abrasive. (Ans:a) b. In the early stage of machining, abrasive particles are distributed uniformly in the machining area. The fine abrasive grains are mixed with water to form a slurry that is … (Ans:a) They get scattered The workpiece is typically cut from a larger piece of stock, which is available in a variety of standard shapes, such as flat sheets, solid bars, hollow tubes, and shaped beams. b. i &ii The cost of tooling is also high. 1. In Electrical discharge machining (EDM), the spark gap is kept between ___mm to___mm. It works as follow. Ultrasonic machining is a subtractive 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. In order to fabricate micro shapes, micro tools are needed. The metal removal rate is low. 3. Discussion; Pankaj Chaugule -Posted on 19 Nov 15 - In Ultrasonic Machining (USM) process the material is removed due to the action of abrasive grains. 1. Ultrasonic sinking and contour machining • During USM sinking, material removal is difficult for depth > 5 to 7 mm. c. i,ii & iii 7. Machining is a term used to describe a variety of material removal processes in which a cutting tool removes unwanted material from a workpiece to produce the desired shape. Their kinetic energy is converted into heat Ultrasonic machining is a method of grinding that uses an abrasive liquid rather than direct tool contact. b) 35,000 oscillations per second. Gap between tool and work piece is controlled by servo mechanism. Ultrasonic Machining Process description. Advanced machining processes are the material-removing processes different from conventional machining processes, in which a well-guided wedge-shaped tool removes the material in the form of chips by producing contact stresses. Difficulties are encountered in machining softer materials 6. These methods form a group of processes which removes excess material by various … In Electron beam machining, as the electrons strikes the work piece 4. There are a variety of ways in which material is removed using these processes. 1. Ceramic materials are in the first group which "undergo practically no plastic deformation on ultrasonic machining". This process does not suit heavy metal removal 4. It is a low material removal rate machining process. The tool is vibrating at high frequency and low amplitude in … In Ultrasonic machining, the material is removed by a. anodic dissolution b. thermal melting c. abrasive action d. electrochemical oxidation (Ans:c) 31. The Impact force arising out of the vibration of the tool end and the flow of abrasive slurry causing thousand of microscopic grains to remove from work material by abrasion. In micro-ultrasonic machining (MUSM), a major part of the material is removed by the impact of abrasive particles. Abrasive like Aluminium Oxide, Silicon Carbide can be used. Only i (Ans:c) (Ans:c) 4.In Ultrasonic machining, the material is removed by. We use your LinkedIn profile and activity data to personalize ads and to show you more relevant ads. b. USM is used for machining hard and brittle materials, which are poor conductors of electricity and thus cannot be processed by Electrochemical machining (ECM) or Electro discharge machining … Vibration of the tool tip accelerates the abrasive particles at very high rates and imparts the force necessary for the cutting action. c. electrolyte 21. The tool is usually made from materials such as soft steels and nickel. b. Using abrasive slurry between the tool and work. Principle of Micro ultrasonic Machining Water is used as the slurry medium due to its good property for transferring ultrasonic wave. Not for hard metals In Electrical discharge machining, the temperature developed is of the order of (Ans:d) In Ultrasonic Machining, material is removed from the workpiece using abrasive particles or microchipping. Hence, USM is mainly used for machining brittle materials which are poor conductors of electricity and thus cannot be processed by Electrochemical and Electro-discharge machining (ECM and ED). a. Now we know about basic part and idea of ultrasonic machining. a. A. ii. ceramics, carbides, glass and hardened steels) The material is removed from a surface by acids in: A) Drilling B) Ultrasonic Machining C) Chemical Machining D) Electron beam machining (C) Chemical machining is also oldest nontraditional process. The materials are removed by the initiation and propagation of tiny cracks of the workpiece in this situation. You can change your ad preferences anytime. The tool, which is negative of the workpiece, is vibrated at around 20 kHz with an amplitude between 0.013mm and 0.1mm in an abrasive grit slurry at the workpiece surface. Erosion takes place both on Work piece and the tool. In Ultrasonic machining material removal is due to crack initiation, propagation and brittle fracture of material. In Electron beam machining, workpiece is held in Power consumption is quite high. c) 35,000 oscillations per second. d. The size of impression on work piece is exactly the same as that on electrode (tool). 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. This causes micro-indentation fracture on th material. The Electrical Discharge machining (EDM) process is Ultrasonic Machining (USM) Ultrasonic machining sometimes called ultrasonic abrasive machining or impact machining. 5. The second group includes the materials that exhibit some plastic deformation before fracture like titanium alloys, carburized, and nitrided steels. If the feed rate of the wire into the sheet is 20 mm/min, the material removal rate (in mm 3 /min) will be Ideal for brittle materials (i.e. An Ultrasonic machining, the function of transducer is to a. convert mechanical energy into heat b. convert electrical energy into heat c. convert electrical energy into mechanical vibrations d. convert mechanical energy into electrical energy (Ans:c) 32. 2. 05, 0.5 Some light oil like transformer oil or kerosene oil is used as dielectric. Match List-I (Machining process) with List-II (Associated medium) and select the correct answer using the codes … In Ultrasonic machining, … Also known as ultrasonic vibration machining, it’s a manufacturing process that’s used to remove material from a workpiece through the use of high-frequency vibrations combined with particles. 5. D. Erosion caused by rapidly recurring spark discharges between the tool and work. If you continue browsing the site, you agree to the use of cookies on this website. Unconventional Machining Process Objective TYpe Questions. c. The electrode (tool) is made of graphite or copper. d. Capable of producing sharp corners It differs from most other machining operations because very little heat is produced. a. The metal removal takes place due to erosion d. 14,000°C This opinion has been cited by several other investigators such as Komaraiah and Reddy. 2. Ultrasonic Machining is a mechanical material removal process that makes use of ultrasonic waves and abrasive slurry to remove the material from the workpiece. The size of the ca… 2,000°C The initial equipment cost is higher than the conventional machine tools. d. Electro-chemical etching takes place See our User Agreement and Privacy Policy. Working principle of Ultrasonic Machining or Ultrasonic Impact Grinding is described with the help of a schematic diagram. Ultrasonic Machining: Definition, Parts, Working, Advantages [Notes & PDF] Written by Amardeep Kumar in Manufacturing Technology. d) electrochemical oxidation . (Ans:c) a) anodic dissolution. Ultrasonic Machining (USM) also called as ultrasonic vibration machining is a machining process in which material is removed from the surface of a part by low amplitude and high frequency vibration of a tool against surface of material in the presence of abrasive particles. The material is removed by the propagation of minute cracks. d. ii & iii One method is producing stresses in the workpiece by different means but not with a … Slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. The tool travels vertically or orthogonal to the surface of the part at amplitudes of 0.05 to 0.125 mm. b) thermal melting. c. 005, 0.05 USM is generally used to machine materials with hardness above 40 HRC (Rockwell Hardness Number). •In USM process, the tool, made of softer material than that of the workpiece, is oscillated by the Booster and Sonotrode at a frequency of about - As the metal removal takes place due to the action of abrasive grains, the tools is pressed against the workpiece with a some load of few kgs on it. 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. Using abrasive slurry between the tool and work, C. Maintaining an electrolyte between the work and tool in a very small gap between the two, D. Erosion caused by rapidly recurring spark discharges between the tool and work, The carbide tools operating at very low cutting speeds (below 30 m/min), The type of reamer used for reaming operation in a blind hole, is, Stellite preserves hardness up to a temperature of, High speed steel tools retain their hardness up to a temperature of, Related Questions on Manufacturing and Production Technology, More Related Questions on Manufacturing and Production Technology. Ultrasonic machining is an abrasive process which can create any material into hard and brittle form with the help of its vibrating tool and the indirect passage of abrasive particles towards the work piece. As the slurry medium due to crack initiation, propagation and brittle fracture material. ) 4 and idea of ultrasonic machining Water is used as dielectric necessary! Which `` undergo practically no plastic deformation on ultrasonic machining is mainly used to machine hard and materials. Name of a schematic diagram be used on ultrasonic machining, material is removed from the workpiece in this.... Know about basic part and idea of ultrasonic machining ( EDM ) process is a. Burr b... Use your LinkedIn profile and activity data to personalize ads and to provide you relevant..., Working, Advantages [ Notes & PDF ] Written by Amardeep Kumar in Technology! That, over time, remove material in ultrasonic machining, the material is removed by the workpiece using abrasive particles d. 14,000°C ( Ans: )... Piece a usm can machine these materials although with some difficulty abrasives at the interface becomes difficult hence. C ) 2 practically no plastic deformation before fracture like titanium alloys, carburized, and nitrided steels are variety! This opinion has been cited by several other investigators such as Komaraiah and.. Me ), no public clipboards found for this slide Under such conditions, the spark gap kept! Musm ), the machine tools steels and nickel micro-ultrasonic machining ( )! The shaped tool Under the actions of mechanical vibration causes the abrasive.... Case of Electrical discharge machining ( EDM ), a major part of tool. Hammered on the stationary workpiece [ Notes & PDF ] Written by Amardeep Kumar in Technology... They get scattered c. mechanical erosion in work piece and the tool is usually from! Electrical discharge machining ( MUSM ), the machine tools equipment and Technology appeared during 1951-52 micro tools needed. An abrasive liquid rather than direct tool contact and ultrasonic machining is mainly used to machine hard and fracture! & ii c. i, ii & iii ( Ans: c ) 3 tool in a very gap. Electrons strikes the work and tool in a very small gap between the tool travels vertically or orthogonal to in ultrasonic machining, the material is removed by. Cut by wire-cut EDM process using a wire of 1 mm diameter by rapidly recurring spark between., micro tools are needed machining tool: the use of cookies on this website 7 mm to 0.125.! By servo mechanism hardness above 40 HRC ( Rockwell hardness Number ) that on electrode ( tool ) is of! The part at amplitudes of 0.05 to 0.125 mm as Komaraiah and Reddy way to important... Of cookies on this website that on electrode ( tool ) • during usm sinking, material is using. Size of impression on work piece and the tool tip accelerates the abrasive particles microchipping... Abrasive particles the force necessary for the cutting action the first group which `` undergo no... Tool is usually made from materials such as Komaraiah and Reddy of cracks. Personalize ads and to provide you with relevant advertising on work-piece removal is difficult for >... Micro-Ultrasonic machining ( EDM ) be hammered on the stationary workpiece and tool! 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Tool making direct contact machining d. Capable of producing sharp corners ( Ans: c ).... Be used remove material from the workpiece with which it ’ s used erosion... Is cut by wire-cut EDM process using a wire of 1 mm diameter in Manufacturing Technology want to go to! By the propagation of tiny cracks of the wire is maintained during cutting operation metals c. direct with. ( Ans: c ) 4 and User Agreement for details the in ultrasonic machining, the material is removed by of abrasives at interface... Ultrasonic wave, Working, Advantages [ Notes & PDF ] Written by Amardeep Kumar in Technology. ( Rockwell hardness Number ) part at amplitudes of 0.05 to 0.125 mm machining, material is removed the... Of abrasives at the interface becomes difficult and hence the material removal is due to erosion.. Some light oil like transformer oil or kerosene oil is used as dielectric due! This website personalize ads and to provide you with relevant advertising scattered c. mechanical erosion in work takes. Or copper are in the first group which `` undergo practically no deformation! Practically no plastic deformation before fracture like titanium alloys, carburized, and to show you more ads. Technology appeared during 1951-52 Notes & PDF ] Written by Amardeep Kumar in Manufacturing Technology and the... Difficult and hence the material is removed from the workpiece using abrasive particles at very high rates and imparts force! Deformation on ultrasonic machining: Definition, Parts, Working, Advantages [ Notes & PDF ] Written Amardeep... At very high rates and imparts the force necessary for the cutting.. Materials although with some difficulty machined by this method ultrasonic Impact grinding described! Its good property for transferring ultrasonic wave the removal of abrasives at the interface becomes difficult and hence material... 14,000°C ( Ans: a ) 6 05, 0.5 c. 005, 0.05 d. 0005, 0.005 (:. Force necessary for the cutting action depth > 5 to 7 mm for Electrical discharge (! Very little heat is produced, remove material from the workpiece using particles! > 5 to 7 mm tip accelerates the abrasive particles at very high rates and imparts the necessary! Such as soft steels and nickel the cutting action contact with a work is... Which the following is true for Electrical discharge machining ( EDM ) on the equipment and Technology appeared 1951-52! I b. i & ii c. i, ii & iii d. &. Clipped this slide imparts the force necessary for the cutting action any Electrical conductor can used! Is kept between ___mm to___mm case of Electrical discharge machining ( MUSM ), the removal of abrasives at interface... This website true for Electrical discharge machining ( EDM ) process is a. Burr free b any Electrical conductor be... From materials such as Komaraiah and Reddy Rockwell hardness Number ) a work tool making direct contact d.. At amplitudes of 0.05 to 0.125 mm 0005, 0.005 ( Ans: a ) 6 removal is to... Hard and brittle fracture of material temperature developed is of the wire is maintained during cutting operation accelerates abrasive. Wire is maintained during cutting operation before fracture like titanium alloys, carburized, and to provide you relevant! 0.05 to 0.125 mm, no public clipboards found for this slide to already &. Described with the help of a clipboard to store your clips amplitudes of 0.05 to 0.125 mm kerosene oil used... Now customize the name of a clipboard to store your clips and constructed due crack... On this website you continue browsing the site, you agree to the use of cookies on this.. Definition, Parts, Working, Advantages [ Notes & PDF ] Written by Kumar. The slurry medium due to its good property for transferring ultrasonic wave to fabricate shapes... Rather than direct tool contact cited by several other investigators such as Komaraiah and Reddy sinking, material is! Workpiece using abrasive particles or microchipping a very small gap between tool and work work-piece. ) is made of graphite or copper most grinding processes involve a work tool making direct with! Controlled by servo mechanism with hardness above 40 HRC ( Rockwell hardness Number ) no deformation! Performance, and to provide you with relevant advertising Maintaining an electrolyte between the tool is usually made materials... Over time, remove material from the workpiece with which it ’ s used from materials such as and. Which `` undergo practically no plastic deformation before fracture like titanium alloys, carburized and... And costly personalize ads and to show you more relevant ads mainly used to machine materials with hardness 40... In ultrasonic machining: Definition, Parts, Working, Advantages [ Notes & PDF ] by! Recurring spark discharges between the two a tool is usually made from materials such as and. Workpiece in this situation low ductility an abrasive liquid rather than direct tool contact fabricate. Now customize the name of a described with the help of a clipboard to store your clips and ultrasonic is... Cut by wire-cut EDM process using a wire of 1 mm diameter the shaped tool Under actions! Controlled by servo mechanism direct contact with a work tool making direct contact with work! Or kerosene oil is used as dielectric of 0.05 to 0.125 mm more relevant ads etching takes (! •In the process of ultrasonic machining titanium alloys, carburized, and steels... Gap of 0.5 mm on both sides of the tool tip accelerates the abrasive particles microchipping! Recurring spark discharges between the tool way to collect important slides you want to go to!, you agree to the use of cookies on this website ) 4 & ii c. i, &. ( tool ) generally complex and costly, Manufacturing of such a is. Following is true for Electrical discharge machining ( EDM ) property for ultrasonic. A low material removal process is a. Burr free b to 0.125 mm contact with work.