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Concept
Ultrasonic machining
Summary
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. The tool travels vertically or orthogonal to the surface of the part at amplitudes of 0.05 to 0.125 mm (0.002 to 0.005 in.). The fine abrasive grains are mixed with water to form a slurry that is distributed across the part and the tip of the tool. Typical grain sizes of the abrasive material range from 100 to 1000, where smaller grains (higher grain number) produce smoother surface finishes.
Ultrasonic vibration machining is typically used on brittle materials as well as materials with a high hardness due to the microcracking mechanics.
An ultrasonically vibrating machine consists of two major components, an electroacoustic transducer and a sonotrode, attached to an electronic control unit with a cable. The abrasive grains in the slurry now act as a free cutting tool as they strike the workpiece thousands of times per second. An electronic oscillator in the control unit produces an alternating current oscillating at a high frequency, usually between 18 and 40 kHz in the ultrasonic range. The transducer converts the oscillating current to a mechanical vibration. Two types of transducers have been used in ultrasonic machining; either piezoelectric or magnetostrictive:
Piezoelectric transducer This consists of a piece of piezoelectric ceramic, such as barium titanate, with two metal electrodes plated on its surface. The alternating voltage from the control unit applied to the electrodes causes the piezoelectric element to bend back and forth slightly, causing it to vibrate.
Magnetostrictive transducer This consists of a cylinder of ferromagnetic material such as steel inside a coil of wire. Magnetostriction is an effect which causes a material to change shape slightly when a magnetic field through it changes.
Official source
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