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SEMINAR REPORT
On
Mechanical Engineering
By
[i]
DEPARTMENT OF MECHANICAL ENGINEERING
RAJKIYA ENGINEERING COLLEGE, BANDA
CANDIDATE’S DECLARATION
I hereby declare that the work which is presented in this seminar, entitled, “ULTRASONIC
MACHINING (USM)”, submitted in partial fulfillment of the requirement for the award of
the degree of Bacholer of Technology in Department of Mechanical engineering Rajkiya
Engineering College, Banda affiliated to Uttar Pradesh Technical University (formerly
Gautam Buddh Technical University) Lucknow is an authentic record of my own work carried
out during the period from August 2017 to November 2017 under the supervision and guidance
of Er. Akshendra Soni, Rajkiya Engineering College, Banda. I also declare that I have not
submitted the matter embodied in this seminar for award of any other degree.
Date:
Place: (CHANDRA KANT SAURABH)
[ii]
CERTIFICATE
Certified that CHANDRA KANT SAURABH (1673440902) has carried out the seminar
Work presented in this entitled “ULTRASONIC MACHINING (USM)” for the award of
Bachelor of Technology from RAJKIYA ENGINEERING COLLEGE, BANDA under my
supervision.
[iii]
ACKNOWLEDGMENTS
I would like to thank my parents for the encouragement and support they showed during this
work for which just expressing a work of thanks would not be sufficient.
This seminar would not have been possible without help and support of my supervisor Er.
Akshendra Soni who has always been up with valuable suggestions in completing this work.
I would like to thanks Er. Shrinkhla Kanojiya for his helpful attitude, cooperation and
encouragement without which this work would have not been possible.
I also thanks to all staff members of the Mechanical Engineering Department for their helps
rendered
Date:
[iv]
ABSTRACT
[v]
CONTENTS
CERTIFICATE I
ACKNOWLEDGE Ii
ABSTRACT Iii
CONTENT Iv
1.1 INTRODUCTION 1
1.2 HOSTORY 2
1.4 PRINCIPLE 3
2.1 WORKING 7
2.6 APPLICATION 12
2.7 ADVANTAGES 12
2.8 DISADVANTAGES 13
REFERENCES 15
[vi]
CHAPTER 1
INTRODUCTION
1.1 INTRODUCTION
Ultrasonic machining is used for machining hard materials and brittle materials.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 workface at a
frequency above the audible range.The workpiece is placed under the face of the tool which is
subjected to high frequency vibration perpendicular to the surface being machined. Abrasive
slurry is conveyed to the working zone between the face of the tool and the surface being
machined. The tool moves towards the workpiece and is subjected to a static driving force.
Repetitive impact of the tool on the grains of the abrasive material lead to the fracture of the
workpiece material and to the creation of a cavity with the shape mirror formed of the tool. The
abrasive particles are propelled or hammered against the workpiece by the transmitted
vibrations of the tool. The particles then microscopically erode the workpiece.
Almost any hard and brittle material, including aluminum oxides, silicon, silicon
carbide, silicon nitride, glass, quartz, sapphire, ferrite, fiber optics, etc., can be
ultrasonically machined.
The tool does not exert any pressure on the work-piece (drilling without drills),
and is often made from a softer material than the work-piece, say from brass, cold-
rolled steel, or stainless steel and wears only slightly.
[1]
The roots of ultrasonic technology can be traced back to research on the
piezoelectric effect conducted by Pierre Curie around 1880. He found that
asymmetrical crystals such as quartz and Rochelle salt (potassium sodium titrate)
generate an electric charge when mechanical pressure is applied. Conversely,
mechanical vibrations are obtained by applying electrical oscillations to the same
crystals. Ultrasonic waves are sound waves of frequency higher than 20,000 Hz.
1.2 HISTORY
• The roots of ultrasonic technology can be traced back to research on the piezoelectric
effect conducted by Pierre Curie around 1880.
• He found that asymmetrical crystals such as quartz and Rochelle salt (potassium
sodium titrate) generate an electric charge when mechanical pressure is applied.
• One of the first applications for Ultrasonic was sonar (an acronym for sound navigation
ranging). It was employed on a large scale by the U.S. Navy during World War II to
detect enemy submarines.
• Today's Ultrasonic applications include medical imaging (scanning the unborn fetus)
and testing for cracks in airplane construction.
[2]
slurry is fed between the tool and workpiece. The impact of the hard abrasive particles fractures
the workpiece thus removing the small particles from the work surface.
1.4 PRINCIPLE
The machining zone (between the tool and the work piece) is flooded with hard
abrasive particles generally in the form of water based slurry.
As the tool vibrates over the work piece, abrasive particles acts as indenter and
indent both work and tool material .
Abrasive particles , as they indent , the work material would remove the
material from both tool and work piece.
In Ultrasonic machining material removal is due to crack initiation, propagation and
brittle fracture of material.
[3]
Conical tool gives twice MRR compared to cylindrical tool.
The brittle behavior of material is important in determining the MRR.
Brittle material can be cut at higher rates than ductile materials.
TRANSDUCER
The high frequency electrical signal is transmitted to traducer which converts
it into high frequency low amplitude vibration.
MAGNETOSTRICTIVE TRANSDUCER
1. Power supply
2. Transducer
3. Tool holder
4. Tool
5. Abrasive slurry
[4]
(Source: [1])
Transducer
Piezoelectric transducers utilize crystals like quartz whose dimensions alter when
being subjected to electrostatic fields.
The charge is directionally proportional to the applied voltage.
To obtain high amplitude vibrations the length of the crystal must be matched to
the frequency of the generator which produces resonant conditions.
Abrasive
Abrasive Slurry
- common types of abrasive
- Boron carbide (B4C) good in general, but expensive
- Silicon carbide (SiC) glass, germanium, ceramics
- Corundum (Al2O3)
- Diamond (used for rubies , etc)
[5]
- Boron silicon-carbide (10% more abrasive than B4C)
Liquid
- Water most common
- Benzene
- Glycerol
- Oils
- High viscosity decreases MRR
The shape of the tool holder is cylindrical or conical, or a modified cone which
helps in magnifying the tool tip vibrations.
Its function is to increase the tool vibration amplitude and to match the vibrator to
the acoustic load. Therefore it must be constructed of a material with good acoustic
properties and be highly resistant to fatigue cracking.
Monel and titanium have good acoustic properties and are often used together with
stainless steel, which is cheaper.
Tool
Tool material should be tough and ductile. Low carbon steels and stainless steels
give good performance.
Tools are usually 25 mm long ; its size is equal to the hole size minus twice the size
of abrasives.
Mass of tool should be minimum possible so that it does not absorb the ultrasonic
energy.
It is important to realize that finishing or polishing operations on the tools are
sometimes necessary because their surface finish will be reproduced in the
workpiece.
Tool and toolholder are often attached by silver brazing.
[6]
CHAPTER 2
WORKING
2.1 WORKING
(Source: [1])
Steps of Working :
1. A.C. power supply is fed in to the U.S. waves generator which converts low frequency
(50 Hz) electrical power to high frequency (20 KHz) electrical power.
2. This high frequency electrical signal is transmitted to the ultrasonic transducer which
converts it in to high frequency low amplitude vibrations.
3. These high frequency vibrations are transmitted to the tool via tool holder.
4. The tool shape is made converse to the desired cavity. The tool is placed very near to
the work surface and the gap between the vibrating tool and the work piece is flooded
with the abrasive slurry made up of fine abrasive particles and suspension medium
(Usually water).
5. As the tool vibrates in its downward stroke, it strikes the abrasive particles. This impact
from the tool propels the grains across the gap between the tool and the work particles
attains K.E. and attains the work surface with a force greater than their own weight.
6. This force is sufficient to remove material from the brittle work piece (like carbide,
glass, ceramic, silicon, titanium, tungsten etc.) and results in a crater on it.
[7]
2.2 PROCESS PARAMETERS
1. Various parameters that affect the ultrasonic machining are:
2. Amplitude of vibration ( 15 to 50 microns)
3. Frequency of vibration (19 to 25 kHz)
4. Feed force (F) related to tool dimensions
5. Feed pressure
6. Abrasive size
7. Abrasive material: Al2O3, SiC, B4C, boron silica carbide, diamond
8. Flow strength of the work material
9. Flow strength of the tool material
10. Contact area of the tool
11. Volume concentration of abrasive in water slurry
12. Tool
(a) Material of tool
(b) Shape
(c) Amplitude of vibration
(d) Frequency of vibration
(e) Strength developed in tool
(g) Gap between tool and work
13. Work material
(a) Material
(b) Impact strength
(c) Surface fatigue strength
14. Slurry
(a) Abrasive—hardness, size, shape and quantity of abrasive flow
(b) Liquid—chemical property, viscosity, flow rate
(c) Pressure
(d) Density
[8]
2.3 Material Removal Rate
TABLE 1
[9]
• The increase of feed force induces greater chipping forces by each grain, which raises
the overall removal rate.
• McGeough (1988) reported that the increase in vibration frequency reduces the removal
rate.
• This trend may be related to the small chipping time allowed for each grain such that a
lower chipping action prevails and causing a decrease in the removal rate.
2. Abrasive Grains
• Both the grain size and the vibration amplitude have a similar effect on the removal
rate.
• According to McGeough (1988), MRR rises at greater grain sizes until the size reaches
the vibration amplitude, at which stage, the MRR decreases.
• When the grain size is large compared to the vibration amplitude, there is a difficulty
of abrasive renewal.
• Because of its higher hardness, B4C achieves higher removal rates than silicon carbide
(SiC) when machining glass.
• The MRR obtained with silicon carbide is about 15 % lower when machining glass, 33
% lower for tool steel, and about 35 % lower for sintered carbide.
• Water is commonly used as the abrasive carrying liquid for the abrasive slurry while
benzene, glycerol, and oils are alternatives.
• The increase of slurry viscosity reduces the removal rate.
• The improved flow of slurry results in an enhanced machining rate.
• In practice a volumetric concentration of about 30 to 35 percent of abrasives is
recommended.
• A change of concentration occurs during machining as a result of the abrasive dust
settling on the machine table.
• The actual concentration should, therefore, be checked at certain time intervals.
• The increase of abrasive concentration up to 40 % enhances MRR.
• More cutting edges become available in the machining zone, which raises the chipping
rate and consequently the overall removal rate.
[10]
• In this regard, the higher the ratio, the lower will be MRR.
• For this reason soft and tough materials are recommended for USM tools.
4. Tool Shape
• Increase in tool area - decreases the machining rate; due to inadequate distribution of
abrasive slurry over the entire area.
• McGeough (1988) reported that, for the same machining area, a narrow rectangular
shape yields a higher machining rate than a square shape.
• Rise in static pressure - enhances MRR up to a limiting condition, beyond which no
further increase occurs.
• Reason - disturbance in the tool oscillation at higher forces where lateral vibrations are
expected.
• According to Kaczmarek (1976), at pressures lower than the optimum, the force
pressing the grains into the material is too small and the volume removed by a particular
grain diminishes.
• Measurements also showed a decrease in MRR with an increase in the hole depth.
• Reason - deeper the tool reaches, the more difficult and slower is the exchange of
abrasives from underneath the tool.
Larger the grit size, faster the cutting rate but surface finish is poor.
Surface finish of 0.38 to 0.25 μm can be expected using abrasives of grit number 240.
[11]
2.6 APPLICATIONS
Machining of cavities in electrically non-conductive ceramics
Used to machine fragile components in which otherwise the scrap rate is high
Used for multistep processing for fabricating silicon nitride (Si3N4) turbine
blades
Large number of holes of small diameter could be machined. 930 holes with 0.32mm
has been reported ( Benedict, 1973) using hypodermic needles
Used for machining hard, brittle metallic alloys, semiconductors, glass,
ceramics, carbides etc.
Used for machining round, square, irregular shaped holes and surface
impressions.
Used in machining of dies for wire drawing, punching and blanking
operations
USM can perform machining operations like drilling, grinding and milling
operations on all materials which can be treated suitably with abrasives.
USM has been used for piercing of dies and for parting off and blanking
operations.
USM enables a dentist to drill a hole of any shape on teeth without any pain
Ferrites and steel parts , precision mineral stones can be machined using
USM
USM can be used to cut industrial diamonds
USM is used for grinding Quartz, Glass, ceramics
Cutting holes with curved or spiral centre lines and cutting threads in glass and
mineral or metallo-ceramics.
2.7 ADVANTAGES
It can be used machine hard, brittle, fragile and non conductive material
No heat is generated in work, therefore no significant changes in physical structure
of work material
Non-metal (because of the poor electrical conductivity) that cannot be
machined by EDM and ECM can very well be machined by USM.
It is burr less and distortion less processes.
[12]
It can be adopted in conjunction with other new technologies like
EDM,ECG,ECM.
2.8 DISADVANTAGES
Low Metal removal rate.
It is difficult to drill deep holes, as slurry movement is restricted.
Tool wear rate is high due to abrasive particles. Tools made from brass, tungsten
carbide, MS or tool steel will wear from the action of abrasive grit with a ratio that
ranges from 1:1 to 200:1.
USM can be used only when the hardness of work is more than 45HRC
[13]
CHAPTER 3
CONCLUSION AND RECOMMENDATION
[14]
REFERENCES
1. www.google.com
2. www.wikipedia.com
3. www.studymafia.org
[15]