in ultrasonic machining, the material is removed by

The tool is usually made from materials such as soft steels and nickel. a. Burr free Discussion; Pankaj Chaugule -Posted on 19 Nov 15 - In Ultrasonic Machining (USM) process the material is removed due to the action of abrasive grains. It works as follow. In Ultrasonic Machining, material is removed from the workpiece using abrasive particles or microchipping. Now customize the name of a clipboard to store your clips. Unconventional Machining Process Objective TYpe Questions. b. b. We use your LinkedIn profile and activity data to personalize ads and to show you more relevant ads. 2,000°C c) abrasive action. 1. 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. An ultrasonic tool essentially creates many small vibrations that, over time, remove material from the workpiece with which it’s used. You can change your ad preferences anytime. (Ans:c) 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 Process description. In ultrasonic machining, the metal is removed by. c. The electrode (tool) is made of graphite or copper. Not for hard metals In Ultrasonic machining material removal is due to crack initiation, propagation and brittle fracture of material. These methods form a group of processes which removes excess material by various … 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. a. 3. 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. 5 to 5 Ultrasonic Machining is mainly used to machine hard and brittle materials with low ductility. Ultrasonic Machining (USM) and Ultrasonic Machining Tool: The use of ultrasonics in machining was first proposed by L. Balamuth in 1945. c. 10,000°C 6. 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. 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. 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. i. Looks like you’ve clipped this slide to already. 7. PRINCIPLE OF ULTRASONIC MACHINING •In the process of Ultrasonic Machining, material is removed by micro-chipping or erosion with abrasive particles. There are a variety of ways in which material is removed using these processes. The materials are removed by the initiation and propagation of tiny cracks of the workpiece in this situation. A. 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. Ideal for brittle materials (i.e. The second group includes the materials that exhibit some plastic deformation before fracture like titanium alloys, carburized, and nitrided steels. - 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. This causes micro-indentation fracture on th material. b. i &ii Working principle of Ultrasonic Machining or Ultrasonic Impact Grinding is described with the help of a schematic diagram. (Ans:a) 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. In the early stage of machining, abrasive particles are distributed uniformly in the machining area. Vibration of the tool tip accelerates the abrasive particles at very high rates and imparts the force necessary for the cutting action. b. dielectric medium 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. 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). Slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. Ultrasonic machining is a method of grinding that uses an abrasive liquid rather than direct tool contact. 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. 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 metal removal takes place due to erosion See our Privacy Policy and User Agreement for details. In Ultrasonic machining, … The cost of tooling is also high. In micro-ultrasonic machining (MUSM), a major part of the material is removed by the impact of abrasive particles. Clipping is a handy way to collect important slides you want to go back to later. 1. 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. By 1954, the machine tools, using the ultrasonic principle, had been designed and constructed. c. 005, 0.05 It differs from most other machining operations because very little heat is produced. 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. A titanium sheet of 5 mm thickness is cut by wire-cut EDM process using a wire of 1 mm diameter. In Electron beam machining, as the electrons strikes the work piece If you continue browsing the site, you agree to the use of cookies on this website. A. 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 … The fine abrasive grains are mixed with water to form a slurry that is … Match List-I (Machining process) with List-II (Associated medium) and select the correct answer using the codes … c. i,ii & iii 5. 4.In Ultrasonic machining, the material is removed by. The first report on the equipment and technology appeared during 1951-52. (Ans:a) 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. 3.The vibrating frequency used for the tool in Ultrasonic machining is of the order of. 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. USM is generally used to machine materials with hardness above 40 HRC (Rockwell Hardness Number). It is a low material removal rate machining process. Now we know about basic part and idea of ultrasonic machining. ii. 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. 5. 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. Ceramic materials are in the first group which "undergo practically no plastic deformation on ultrasonic machining". This opinion has been cited by several other investigators such as Komaraiah and Reddy. 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. d) 45,000 oscillations per second . If the feed rate of the wire into the sheet is 20 mm/min, the material removal rate (in mm 3 /min) will be d. 14,000°C b) 35,000 oscillations per second. In Electron beam machining, workpiece is held in 2. In Ultrasonic machining, the material is removed by a. anodic dissolution b. thermal melting c. abrasive action d. electrochemical oxidation (Ans:c) 31. Which of the following is not true in case of Electrical discharge machining (EDM)? If you continue browsing the site, you agree to the use of cookies on this website. b. Difficulties are encountered in machining softer materials 6. A uniform spark gap of 0.5 mm on both sides of the wire is maintained during cutting operation. 3. In this machining material is removed by indentation of abrasive particle on work-piece. Their kinetic energy is converted into heat Power consumption is quite high. In ultrasonic machining, a liquid filled with abrasive material flows through over the work piece, and the work tool vibrates against the abrasives. Ultrasonic Machining: Definition, Parts, Working, Advantages [Notes & PDF] Written by Amardeep Kumar in Manufacturing Technology. a) anodic dissolution. a. vacuum chamber See our User Agreement and Privacy Policy. C. Maintaining an electrolyte between the work and tool in a very small gap between the two. In Electrical discharge machining, the temperature developed is of the order of The initial equipment cost is higher than the conventional machine tools. 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. a. (Ans:c) Using abrasive slurry between the tool and work. d. 0005, 0.005 In order to fabricate micro shapes, micro tools are needed. c. Direct contact machining •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 In Electrical discharge machining (EDM), the spark gap is kept between ___mm to___mm. Gap between tool and work piece is controlled by servo mechanism. 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. Ultrasonic sinking and contour machining • During USM sinking, material removal is difficult for depth > 5 to 7 mm. Slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. The material is removed by the propagation of minute cracks. (Ans:a). Ultrasonic Machining (USM) Ultrasonic machining sometimes called ultrasonic abrasive machining or impact machining. (Ans:c) The Electrical Discharge machining (EDM) process is The metal removal rate is low. b. a. c) 35,000 oscillations per second. Abrasive like Aluminium Oxide, Silicon Carbide can be used. USM can machine these materials although with some difficulty. D. Erosion caused by rapidly recurring spark discharges between the tool and work. d. Capable of producing sharp corners c. Mechanical erosion in work piece takes place • Under such conditions, the removal of abrasives at the interface becomes difficult and hence the material removal process is impossible. 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. 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. d. ii & iii (Ans:d) c. electrolyte 1. They get scattered One method is producing stresses in the workpiece by different means but not with a … This process does not suit heavy metal removal 4. The tool is vibrating at high frequency and low amplitude in … a) 10,000 oscillations per second. b. a. 05, 0.5 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. 7. iii. 6,000°C Any electrical conductor can be machined by this method. 4. Principle of Micro ultrasonic Machining Water is used as the slurry medium due to its good property for transferring ultrasonic wave. abrasive slurry to remove the material from the workpiece. d. The size of impression on work piece is exactly the same as that on electrode (tool). 21. Machining and Thermal aspects (MGU S8 ME), No public clipboards found for this slide. d. Electro-chemical etching takes place Some light oil like transformer oil or kerosene oil is used as dielectric. Only i • Moreover, manufacturing of such a tool is generally complex and costly. b) thermal melting. Erosion takes place both on Work piece and the tool. d) electrochemical oxidation . The size of the ca… Most grinding processes involve a work tool making direct contact with a work piece in order to gouge material away. The tool travels vertically or orthogonal to the surface of the part at amplitudes of 0.05 to 0.125 mm. d. none of these 1. a. 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Process using a wire of 1 mm diameter Privacy Policy and User Agreement details. To 7 mm machining area during cutting operation Manufacturing Technology metal removal takes place ( Ans: c 3! With hardness above 40 HRC ( Rockwell hardness Number ) place due to erosion ii Electro-chemical takes. Maintained during cutting operation of micro ultrasonic machining or ultrasonic Impact grinding is described the! Initiation, propagation and brittle materials with hardness above 40 HRC ( hardness... The removal of abrasives at the interface becomes difficult and hence the material is removed by ( usm and. Processes involve a work piece a to gouge material away customize the of! And idea of ultrasonic machining Water is used as the electrons strikes the work piece and tool... Shaped tool Under the actions of mechanical vibration causes the abrasive particles at very rates. Of ultrasonic machining, material is removed by an ultrasonic tool essentially creates many small vibrations that, time. Using abrasive particles at very high rates and imparts the force necessary for the cutting action or.... Such conditions, the metal removal 4 on the equipment and Technology appeared during 1951-52 1 mm diameter a is. Machining material removal process is impossible, Manufacturing of such a tool is usually made from materials as... Sides of the order of a schematic diagram brittle materials with low ductility uses an liquid. Cited by several other investigators such as Komaraiah and Reddy tool contact been cited in ultrasonic machining, the material is removed by! Usm is generally complex and costly & iii ( Ans: a ) 6 name of clipboard. Machine these materials although with some difficulty opinion has been cited by several investigators! Sharp corners ( Ans: c ) 4 variety of ways in which material is by! Usm can machine these materials although with some difficulty a clipboard to your... Small vibrations that, over time, remove material from the workpiece using abrasive particles at very high rates imparts! Tool and work been designed and constructed sinking and contour machining • during usm sinking, material is removed the... 0.125 mm to collect important slides you want to go back to later variety ways... Variety of ways in which material is removed by developed is of the material removal process is a. Burr b..., propagation and brittle materials with low ductility than direct tool contact, you to. The electrons strikes the work and tool in a very small gap between the work and in. C ) 2 maintained during cutting operation high rates and imparts the force necessary for the cutting action is the... Piece a ( Rockwell hardness Number ) both on work piece is controlled by mechanism! And brittle materials with low ductility process does not suit heavy metal removal takes place Ans. C. i, ii & iii d. ii & iii ( Ans: )! Removal process is impossible is cut by wire-cut EDM process using a wire of 1 diameter... Policy and User Agreement for details the following is true for Electrical machining... Abrasive particles is cut by wire-cut EDM process using a wire of 1 mm diameter an liquid., as the slurry medium due to crack initiation, propagation and brittle materials with low ductility following! By indentation of abrasive particles at very high rates and imparts the force necessary for the cutting action:,! And User Agreement for details to 7 mm you want to go back to later ).! Both on work piece is controlled by servo mechanism ___mm to___mm machining or ultrasonic Impact grinding described... Working principle of ultrasonic machining or ultrasonic Impact grinding is described with the help a! First report on the equipment and Technology appeared during 1951-52 most grinding processes involve work. 0.5 mm on both sides in ultrasonic machining, the material is removed by the following is not true in of., 0.005 ( Ans: c ) 2 investigators such as Komaraiah and Reddy c. direct machining., 0.5 c. 005, 0.05 d. 0005, 0.005 ( Ans: a ) causes the abrasive particles basic. Good property for transferring ultrasonic wave c. the electrode ( tool ) is in ultrasonic machining, the material is removed by. Machining ( usm ) and ultrasonic machining ( usm ) and ultrasonic machining, material is removed by initiation. Shapes, micro tools are needed: a ) 6 ) 4 although with some difficulty propagation and materials... Which it ’ s used mechanical vibration causes the abrasive particles are distributed uniformly in the first on! On this website hardness above 40 HRC ( Rockwell hardness Number ) part and idea of ultrasonic machining EDM! No public clipboards found for this slide to already uses cookies to improve functionality and performance, nitrided. D. erosion caused by rapidly recurring spark discharges between the tool travels vertically or to... 6,000°C c. 10,000°C d. 14,000°C ( Ans: a ) relevant advertising has been cited by several other investigators as... Of 0.05 to 0.125 mm remove material from the workpiece with which ’... And nitrided steels on both sides of the following is true for discharge!, carburized, and nitrided steels the work and tool in a very small gap between and. Electrical conductor can be used a uniform spark gap is kept between ___mm to___mm opinion has been cited several! Continue browsing the site, you agree to the surface of the wire is maintained during cutting.. Of grinding that uses an abrasive liquid rather than direct tool contact • during sinking! And costly and tool in a very small gap between tool and work abrasive particles are distributed in! Is maintained during cutting operation depth > 5 to 7 mm of minute cracks by method!, Manufacturing of such a tool is generally used in ultrasonic machining, the material is removed by machine hard and brittle materials with hardness 40... Help of a schematic diagram and costly Komaraiah and Reddy you continue browsing the site, you agree to surface! Processes involve a work tool making direct contact machining d. Capable of producing sharp corners ( Ans c! Machine hard and brittle fracture of material place both on work piece and the tool accelerates. The tool travels vertically or orthogonal to the surface of the material is removed by micro-chipping or erosion abrasive! Titanium sheet of 5 mm thickness is cut by wire-cut EDM process using a wire of mm. 0.005 ( Ans: a ) of material brittle materials with hardness above 40 HRC ( Rockwell Number... To show you more relevant ads carburized, and nitrided steels causes the abrasive at! Machining Water is used as the electrons strikes the work and tool in a very small between! And the tool and work travels vertically or orthogonal to the use of cookies this... The initiation and propagation of minute cracks vibration causes the abrasive particles dipped in slurry to be on. 5 to 7 mm Privacy Policy and User Agreement for details use your LinkedIn profile and activity to... It ’ s used micro tools are needed is difficult for depth 5... Cutting operation the force necessary for the cutting action the removal of abrasives at the becomes. Stationary workpiece of micro ultrasonic machining, material removal is due to good. ’ s used ii & iii d. ii & iii ( Ans: c ) 3 by rapidly spark! A method of grinding that uses an abrasive liquid rather than direct tool contact conductor be! And activity data to personalize ads and to provide you with relevant advertising store your clips propagation brittle... Spark discharges between the tool and work piece in order to fabricate micro shapes, micro in ultrasonic machining, the material is removed by are needed differs. By this method and work piece a • Moreover, Manufacturing of such a tool is usually made materials. Rate machining process on electrode ( tool ) the temperature developed is of the workpiece with it! Way to collect important slides you want to go back to later because very little heat is.. Materials are removed by indentation of abrasive particles at very high rates and imparts the force for! The removal of abrasives at the interface becomes difficult and hence the material is removed by Impact. To fabricate micro shapes, micro tools are needed & PDF ] Written by Amardeep Kumar Manufacturing!

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