Ultrasonic Machining USM

Vibrations are either piezo-electric or magnetostrictive-transducer generated. 

Tool materials vary with application and allowable tool wear during machining. Common tool materials are mild steel, stainless steel, tool steel, aluminum, brass and carbides (higher wear rates are experienced with aluminum and brass). 

Abrasive grit is available in many grades and material types. Materials commonly used are boron carbide, aluminum oxide, diamond and silicon carbide. 

Liquid medium can be water, benzine or oil. Higher viscosity mediums decrease material removal rates. Rotary USM a rotating diamond coated tool is used for drilling and threading, but with no abrasive involved. 

Ultrasonic cleaning uses high-frequency sound waves in a liquid causing cavitation, which cleans the surface of the component, similar to a scrubbing action. Used to remove scale, rust, etc. 

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Ultrasonic machining (USM) is also of particular importance when very hard type materials are to be cut. As an assist to drilling, HDM energy can extend the drill life when producing holes in reinforced plastics. If the plastic is conductive, electrical discharge machining (EDM) or electrochemical machining (ECM) may be useful. 

Ultrasonic machining (USM) is a method in which a tool called sonotrode and free abrasives are used. The sonotrode vibrates at a very high frequency of about 20 to 40 KHz and drives the abrasive to create a brittle breakage on the workpiece surface. Since material removal is based on the brittle breakage, this... 

Compared to other micromachining processes such as micro-EDM, micro-USM (Ultrasonic machining), micro-LBM (laser beam machining), and tool-based micromachining, the initial setup as well as mnning cost of EMM is lesser. 

The dimensions of the work piece are determined by the size of the abrasive particles. Micro-ultrasonic machining ( xUSM) can be realized by using submicron particles. The USM process is able to machine any material, but is more efficient on brittle materials. The abrasive particles have to be harder than the work piece material. 

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