ULTRASONIC MACHINING PROCESS�PREPARED BY-ER R PATTANAYAK

Mayurbhanj School Of Engineering, Baripada

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Working Principle of Ultrasonic Machining�

The time spent on ultrasonic machine entirely depends on the frequency of the vibrating tool. It also depends on the size of grains of the abrasive slurry, the rigidity and the viscosity as well. The grains used in the abrasive fluid are usually boron carbide or silicon carbide as they are rigid than others. The used abrasive can be carried away easily if the viscosity of the slurry fluid is less.

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WORKING PROCESS

Working of Ultrasonic Machining is: there is gap between tool and work piece about 0.25 mm. The tool is made up of ductile material. Between tool and work piece, there is a slurry of abrasive.

Abrasive gets embedded into the tool and during the downward journey of the tool, abrasives hammer the work piece, removing material.

This material will be flushed away from the machining area by the flow of the slurry tool is made slightly tapered to produce straight holes.

Upon increasing the viscosity of the carrier fluid material removal rate decreases due to difficulty in flushing. By increasing the frequency, MRR will increase because the number of impacts per unit time will increase.

By increasing the amplitude, MRR will increase due to the increase in the momentum of abrasives.

The amplitude of the vibration may vary from 5 to 75 µm and frequency may vary from 19 to 25 kHz.

By increasing the concentration of abrasives, the impact will be there at more places which increases MRR (Material Removal Rate).

But when the concentration increases beyond a certain value, due to Collision between the abrasives momentum is lost, decreasing the MRR.

By increasing the size of the abrasive, an impact will appear in the larger area. But when the size increases beyond a certain value, the momentum of abrasives will decrease.

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