Review on ultrasonic machining

doi:10.1016/S0890-6955(97)00036-9

International Journal of Machine Tools and Manufacture

Volume 38, Issue 4, March 1998, Pages 239-255

https://doi.org/10.1016/S0890-6955(97)00036-9 Get rights and content

Abstract

Ultrasonic machining is of particular interest for the cutting of non-conductive, brittle workpiece materials such as engineering ceramics. Unlike other non-traditional processes such as laser beam, and electrical discharge machining, etc., ultrasonic machining does not thermally damage the workpiece or appear to introduce significant levels of residual stress, which is important for the survival of brittle materials in service. The fundamental principles of ultrasonic machining, the material removal mechanisms involved and the effect of operating parameters on material removal rate, tool wear rate and workpiece accuracy are reviewed, with particular emphasis on the machining of engineering ceramics. The problems of producing complex 3-D shapes in ceramics are outlined.

Section snippets

An overview of ultrasonic machining and applications

Ultrasonic machining (USM) is a non-conventional mechanical material removal process generally associated with low material removal rates, however its application is not limited by the electrical or chemical characteristics of the workpiece materials. It is used for machining both conductive and non-metallic materials; preferably those with low ductility 1, 2, 3, 4, 5and a hardness above 40 HRC 6, 7, 8, 9, 10, 11, 12, e.g. inorganic glasses, silicon nitride, nickel/titanium alloys, etc. 13, 14,

The ultrasonic generator and ultrasonic transducer

With a conventional generator system, the horn and tool are set up and mechanically tuned by adjusting their dimensions to achieve resonance. Recently, however, resonance following generators have become available which automatically adjust the output high frequency to match the exact resonant frequency of the horn/tool assembly [6]. They can also accommodate any small errors in set up and tool wear, giving minimum acoustic energy loss and very small heat generation [33]. The power supplied

Material removal mechanisms

Extensive work on the mechanism of material removal has been done by Shaw [35], Miller [79], Cook [80], Rozenberg et al. [7]and others 22, 23, 43, 60. These mechanisms are detailed in Fig. 6 and comprise:-

•
Mechanical abrasion by direct hammering of the abrasive particles against the workpiece surface 10, 28, 34, 35, 37, 40, 50, 60, 70, 81;
•
Micro chipping by impact of the free moving abrasive particles 28, 35, 37, 50, 70, 81, 82;
•
Cavitation effects from the abrasive slurry 10, 27, 35, 48, 50, 82;
•

Tool wear

Tool wear is an important variable in USM, affecting both MRR and hole accuracy 38, 28, 87, 94, 98. The complex tool wear pattern in USM can be divided into longitudinal wear, W_L 71, 87, 94, and lateral/side/diametral wear, W_D [99], some of which will occur as a result of cavitation or suction wear 38, 71, 75, 100.

The effect of USM on workpiece surface finish/accuracy

USM does not generate significant heating which might otherwise lead to the development of a thermally damaged layer/zone or residual stress. Abrasive grain size has a significant influence on workpiece accuracy and surface finish 4, 23, 26, 36, 40, 73, 82, 94. A decrease in abrasive grain size during USM leads to lower Ra values, see Fig. 14. In addition, the accuracy of the machined hole is improved 3, 10, 13, 28, 35, 41, 59, 66, 70, 75, 81and a better surface finish is obtained on the bottom

Horn and tool design

The theory and art of designing horns has been reviewed by several authors, but it is not as yet fully understood 7, 63, 67, 104, 105, 106. Traditional methods of acoustic horn design are based on a differential equation which considers the equilibrium of an infinitesimal element under the action of elastic and inertia forces, which is then integrated over the horn length to achieve resonance 56, 106, 107. The horn length depends on the working frequency and has no effect on energy

Conclusions

1.
USM is a non-thermal process which does not rely on a conductive workpiece and is preferable for machining workpieces with low ductility and hardness above 40 HRC.
2.
USM is believed to be a stress and damage free process.
3.
For contour USM a resonance following generator is recommended because it can automatically adjust the output high frequency to match the exact resonant frequency of the horn/tool assembly. Such a generator can also accommodate any small errors in set up and tool wear, giving

Acknowledgements

The authors would like to thank Professors K. B. Haley, Head of the School of Manufacturing and Mechanical Engineering and M. H. Loretto, Director of the IRC in Materials for High Performance Applications for the provision of laboratory facilities. Additional thanks go to Dr. J. Woodthorpe at T and N Technology Limited and A. Corfe and D. Jones at Rolls-Royce plc for their technical advice and financial support. Finally thanks go to the Committee of Vice-Chancellors and Principals (CVCP) of the

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Review on ultrasonic machining

Abstract

Section snippets

An overview of ultrasonic machining and applications

The ultrasonic generator and ultrasonic transducer

Material removal mechanisms

Tool wear

The effect of USM on workpiece surface finish/accuracy

Horn and tool design

Conclusions

Acknowledgements

Int. J. MTDR

J. Materials Processing Technology

Int. J. MTDR, Pergamon Press

Annals of the CIRP

7 Int Conf on Computer-Aided Prod. Engg.

Ultrasonics

Ultrasonics

J. Mech. Working Technology

Precision Engg.

Ultrasonics

Ultrasonics

Ultrasonics

Wear

Wear

Tribology International

Wear

Wear

Int. J. Mach. Tools Manuf

Wear

Annals of CIRP

Wear

Tribology Int.

Tribology Int.

Wear

Versatile performance of ultrasonic machining

Cer. Bull.

Ultrasonic machining – II. Operating conditions and performance of ultrasonic drills

Philips Tech. Rev.

Influence of properties of abrasive materials on the effectiveness of ultrasonic machining of ceramics

Sov. Powder Metallurgy and Metal Cer.

Ultrasonic manufacturing process: Ultrasonic machining (USM) and ultrasonic impact grinding (USIG)

The Carbide and Tool J.

Design of velocity transformers for ultrasonic machining

Electrical India

Improving ultrasonic machining rates – some feasibility studies

J. Engg. for Ind., Trans. of the ASME

Ultrasonic machining – A review

The Prod. Engineer

Abrasive methods engineering

Industrial Press

Kinematics of the dimensional ultrasonic machining method

Machines and Tooling

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J. Fac. Engg. Tokyo Univ.

Ultrasonic vibrations assist cutting tools

Metalworking Prod.