How does ultrasonic assisted machining realize?

The ultrasonic assisted machining process has been recognized as a leading, non-traditional high-precision machining process. Recently, it has been developed for processing various advanced and difficult-to-process brittle materials, such as reinforced composite materials, ceramics and metal alloys. The ultrasonic assisted machining can obtain a very high surface finish efficiently and economically. The ultrasonic assisted machining process has also been shown to reduce cutting forces and increase tool life when machining very hard and brittle materials and it was first used in the late 1920s. So, how exactly does ultrasonic assisted machining realize? Let me introduce that to you in the following contents.

Here is the content list:

• What is ultrasonic assisted machining?

• What is the working principle of ultrasonic assisted machining？

What is ultrasonic assisted machining?

ultrasonic assisted machining is a subtractive manufacturing process that removes the high-frequency and low-amplitude vibrations generated on the surface of the material by the tool in the presence of fine abrasive particles from the surface of the part. The tool travels vertically or perpendicular to the surface of the part at an amplitude of 0.05 to 0.125 mm (0.002 to 0.005 inch). The fine abrasive particles are mixed with water to form a slurry, which is distributed on the parts and tips of the tool. The typical grain size of abrasives is 100 to 1000, where smaller grains (higher grain numbers) can produce a smoother surface finish. Ultrasonic assisted machining process is usually used for brittle materials and materials with high hardness due to microcrack mechanics.

What is the working principle of ultrasonic assisted machining？

Mainly, the working principle of ultrasonic assisted machining is to make the interaction between the tool and the workpiece a microscopically non-monotonous process to promote chip separation and reduce processing force. It can also reduce the deformation area in the workpiece being machined, thereby improving the surface integrity of the machined part. To put it in a more specific way, ultrasonic assisted machining performs physical operations through micro-debris or corrosion mechanisms on the surface of the workpiece. Since the abrasive slurry is kept in motion through high-frequency, low-amplitude vibration, the impact force of the abrasive is very large, resulting in higher contact stress. These high contact stresses are achieved by the small contact area between the slurry particles and the surface of the workpiece. Brittle materials fail due to cracking mechanisms, and these high stresses are sufficient to remove micro-scale chips from their surfaces. The entire material will not fail due to local stress areas. The average force of the slurry particles hitting the surface of the workpiece and producing rebound can be quite gentle. Because ultrasonic vibration processing does not use subtractive methods that alter the physical properties of the workpiece (e.g., thermal, chemical, or electrical processes), it has many useful applications for materials that are more brittle and sensitive than conventionally machined metals. Materials commonly processed using ultrasonic methods include ceramics, carbides, glass, gemstones and hardened steel.

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