Development of ultrasonic-assisted machining

Ultrasonic-assisted machining, also known as ultrasonic vibration machining, is a process in which material is removed from the surface of a part by low amplitude and high-frequency vibration of the tool against the surface of the material in the presence of abrasive particles.

Here is the content list:

l Two-dimensional ultrasonic mechanic technology

l Microfine ultrasonic processing

l CNC ultrasonic processing

Two-dimensional ultrasonic mechanic technology

With the improvement of the precision requirements of difficult-to-machine materials, especially aerospace parts, one-dimensional ultrasonic processing has not been able to meet the needs of production, two-dimensional ultrasonic vibration processing came into being. Ultrasonic elliptical vibration cutting has been the attention of the international academic and business community, the United States, the United Kingdom, Germany, and Singaporean universities, as well as the domestic Beijing University of Aeronautics and Astronautics and Shanghai Jiao Tong University, has begun research work in this area. The Japanese business community has started practical research in this area. Chandra Nath et al, studied the effect of carbide tip arc radius under ultrasonic elliptical vibration cutting in which the effect of tool geometry, especially the arc radius of the tool, on the one-dimensional ultrasonic vibration cutting performance was described. Using experiments, it was shown that ultrasonic elliptical vibration cutting performed significantly better in all aspects with tool arc radii of 0.6 mm or lower (e.g., 0.2 mm or 0.4 mm) and higher arc radii (e.g., 0.8 mm). The main reason for this is the rapid wear of the tool, the breakage of brittle materials, and the adhesion to the tool. Ultrasonic elliptical cutting can obtain more practical ultra-precision molds, which are successfully applied to glass molding. Our country has designed high-frequency ultrasonic elliptical vibration precision cutting, which has the effect of reducing cutting force and improving machining accuracy compared with general elliptical vibration and ordinary low-frequency ultrasonic vibration and can adopt higher cutting speed, thus can improve the efficiency. However, there is still a lot of work to be done in the theory and application of ultrasonic elliptical vibration cutting. In particular, the ultra-precision cutting processing of hard and brittle materials, the ultra-precision cutting processing of micro-fine parts and micro-fine molds need further in-depth research.

Microfine ultrasonic processing

Microfine ultrasonic processing in principle is similar to conventional ultrasonic processing, is achieved by reducing the tool diameter, abrasive size, and ultrasonic amplitude. Microfabrication represented by micromechanics is an important part of modern manufacturing technology. The wide application of brittle and hard materials such as crystalline silicon, optical glass, and engineering ceramics in micromechanics has made the high-precision three-dimensional microfabrication technology of brittle and hard materials an important research topic in manufacturing industries all over the world. Compared with EDM, electrolytic processing, laser processing, and other technologies, ultrasonic processing does not depend on the electrical conductivity of the material and no thermophysical effect, compared with photolithography processing and processing of high depth to width ratio of a three-dimensional shape, which determines the ultrasonic processing technology in ceramics, semiconductor silicon and other non-metallic hard and brittle materials processing has a unique advantage. 

CNC ultrasonic processing

At present, the level of modernization of the manufacturing industry continues to improve, the machine tool to the direction of continuous development of CNC, while the vast majority of manufacturing industries and enterprises in China's production and processing equipment is still the traditional machine tools, such as lathes, milling machines, grinding machines, drilling machines, boring machines, etc., the tool relative to the workpiece for linear motion, making its processing accuracy far from meeting demand, directly affecting the survival and development of enterprises. The application of ultrasonic machining technology to CNC machine tools, making the tool relative to the workpiece for irregular motion, so that the workpiece accuracy can be further improved.

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