Lecture series on manufacturing processes ii by prof. Ultrasonic machining is a nontraditional machining process. Ultrasonic machining effects on the surface finish and strength of silicon carbide ceramics article pdf available in international journal of manufacturing technology and management 72. Stationary or conventional ultrasonic machining usm accomplishes the removal of material by the abrading action of a gritloaded slurry, circulating between the workpiece and a. The two electrodes workpiece and tool is immersed in an electrolyte such as nacl. Most grinding processes involve a work tool making direct contact with a work piece in order to gouge material away. Ultrasonic machining national institute of technology. Types of machining and operations, machine tools, cutting tools lathe, drilling. Apr 15, 20 ultrasonic machining introduction ultrasonic machining is a nontraditionalmechanical means of uniform stock materialremoval processit is applicable to both conductive andnonconductive materials. Week1 machine shopturning and other machines batch i. Metal casting is a labour intensive process automation. Abrasive jet machining ajm water jet cutting wjc and abrasive water jet machining awjm magnetic abrasive finishing maf and its modelling 3.
Ultrasonic machining is a mechanical type nontraditional machining process. Ultrasonic machining usm is a mechanical material removal process used to. Machinability of the work material is independent of its physical and mechanical properties. It is also known as ultrasonic impact grinding is an operation that involves a vibrating tool fluctuating the ultrasonic frequencies in order to remove the material from the work piece. Modeling the material removal rate in ultrasonic machining. The shape and the dimensions of the workpiece depend on those of the tool. Modern machining processes presents unconventional machining methods which are gradually commercial acceptance. Mechanicaltype advanced machining processes mamp are of various types, as shown in figure 11. I the machining medium is solid grains suspended in an abrasive slurry.
Nptel video lectures, iit video lectures online, nptel youtube lectures, free video lectures, nptel online courses, youtube iit videos nptel courses. Ultrasonic machining usm is an effective method for fabricating various structures on hard brittle materials. Chemical machining for some special purposes can also be achieved by using a jet of reactive gas, e. Plasma is defined as a gas that has been heated to a sufficiently high. Jntua college of engineering, automous syllabus book as per r regulations.
In ultrasonic machining usm and water jet machining wjm machining, material removal occurs due to mechanicalabrasion ma action. Principle of ultrasonic machining during one strike, the tool moves down from its most upper remote position with a starting speed at zero, then it speeds up to finally. Ultrasonic machining is a nontraditional process, in which abrasives contained in a slurry are driven against the work by a tool oscillating at low amplitude 25100 microns and high frequency 1530 khz. Ultrasonic machining and electrical discharge machining d. Machining ultrasonic machining the industrial resource. In the process, workpiece is taken as anode and tool is taken as cathode. Titanium is known as the metal of the future because of its excellent combination of properties such as high strengthtoweight ratio, low thermal conductivity, and high corrosion resistance. Rotary ultrasonic assisted machining ruam processes have been recognized as leading, nontraditional, highprecision machining processes that have been recently developed to machine a vast range. An introduction to machining practices cornell university.
In order to cut harder materials like metals or granite, an abrasive material is. Automatic control including intelligent control and adaptive control, also tools in processing as an attachment and load matching system are trends in ultrasonic machining tool. Chemical machining working principle, application, advantages. Advanced casting processes metal mould casting continuous casting squeeze casting vacuum mould casting evaporative pattern casting ceramic shell casting 6 3. Pdf while making a part from raw material, one may require bulk removal of material, forming cavitiesholes and. Mechanical machining i jet machining and ultrasonic machining usm are typical examples of single action, mechanical non traditional machining processes. Neppiras until recently ultrasonic machining meant the hammer action of a tool tip which drives an abrasive into the workpiece and cuts out a hole in its own image. Hadi is with the manufacturing department, university of tabriz, tabriz 51664, iran corresponding author to provide phone. Jain, department of mechanical engineering, iit kanpur. Ultrasonic enhancement of an electrochemical machining. Electron beam machining ebm laser beam machining lbm processes 2.
Lecture notes on modern manufacturing process dr pramod. Based on the dynamic analysis of ultrasonic vibration machining system, the best working state is achieved through ansys parameter optimization design method. Usm is a versatile machining process as far as properties of materials are concerned. In electro chemical machining an electrolyte acts as a current carrier.
Mechanism analysis of ultrasonic machining based on finite. Introduction the technology of high power ultrasonics, already extensively applied at ewi in the fields of welding, solderingbrazing and additive manufacturing, is now being extended to the field of ultrasonic machining. The electrolyte in ecm should have high electrical conductivity, low viscosity, high specific heat, chemical stability, resistance to form a passivating film on the workpiece surface, non. The vibration exciter, a magnetostrictive transducer 1, is fixed to the body 2 of the acoustic head using the shoulder 3. This is known as gaseous chemical machining or hot chlorine machining and can be used for deburring of metal parts. Usm is abrasive machining method but laser beam machining is. Oct 22, 2008 lecture series on manufacturing processes ii by prof.
Water jet machining working principle, advantages and. Ultrasonic machining experiments were then carried out to machine alumina, zirconia, quartz, sodalime glass, ferrite and lif. The machining medium is solid particles suspended in abrasive media abrasive slurry in the former while high pressure fluid jet is employed in latter. Usm is mechanical material removal process or an abrasive process used to erode holes or. Chemical machining 632014 hareesha n g, dept of aero engg, dsce 2 3. Usm is suitable for machining of refractory type of material while ajm are for super alloys and refractory. Plasma arc machining pdf plasma pdftex def not arc machining is a nontraditional thermal process. Machining of titanium, however, is considered as cumbersome with the conventional manufacturing practices, and there is a critical need of developing and establishing costeffective methods of. This section deals with two commonly used mamp, viz. Principle, working, equipments, application, advantages, and disadvantages.
Difference between grinding and milling the abrasive grains in the wheel are much smaller and more numerous than the teeth on a milling cutter. Unlike other nontraditional processes such as laser beam, and electrical discharge machining, etc. Thermal metal removal processes methods like plasma arc machining, neutral particle etching, electric discharge machining, hot machining, electron beam machining and laser beam machining. 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. In ultrasonic machining, an electrical hfsignal is transmitted via induction through a small air gap from a stationary coil located on the spindle to a rotating coil located on the hsk toolholder. Ebm can provide holes of any shape by combining beam deflection. The tool that is vibrated at ultrasonic frequency drives the abrasive to create a brittle breakage on the workpiece surface. Ecm can machine highly complicated and curved surfaces in a single pass. Schematic of ultrasonic machine tool usm is primarily targeted for the machining of hard and brittle materials dielectric or conductive such as boron carbide, ceramics, titanium carbides, rubies, quartz etc. May 12, 2017 electrochemical machining ecm is a machining process in which electrochemical process is used to remove materials from the workpiece. Ultrasonic machining, water jet machining, abrasive water jet machining. Advanced welding processes details of electron beam welding ebw laser beam welding lbw ultrasonic welding usw 6 4. Processes likeabrasive jet machining water jet machininglaser beam machininghot machiningplasma arc machininghave also been included.
Nov 29, 2016 ultraprecision machining refers to the ultimate ability of a manufacturing process wherein processing of a material at its lowest scale that is, at the atomic scale, is achieved. Ultrasonic machining basic terms and working youtube. Pdf ultrasonic machining effects on the surface finish. Usm is grouped under the mechanical group ntm processes. Ultrasonic machining is a method of grinding that uses an abrasive liquid rather than direct tool contact. Download as pptx, pdf, txt or read online from scribd. Advanced processes include electrical and chemical means of material removal, as well as the use of abrasive jets, water. Ultrasonic machining from the technology data exchange linked to trusted tde listed vendors.
Manufacturing process technology ii dvd media storage type. Wjm can be used to cut softer materials like plastic, rubber or wood. Silfex ultrasonic machining, also known as ultrasonic impact grinding, combines ultrasonic vibrations with abrasive slurry to create cavities of any shape in hard, brittle materials silicon, silicon nitride, silicon carbide, glass, alumina, quartz, sapphire, graphite. Photochemical machining suron precision technology. Influence of main machining parameters such as spindle speed, abrasive grit size, vibration amplitude on the material removal rate mrr was studied. Situations and development trends of ultrasonic machining. Unit ii mechanical energy based processes 10 abrasive jet machining water jet machining abrasive water jet machining ultrasonic machining. The ultrasonic machining of silicon carbide alumina composites. A single tool can be used to machine a large number of pieces without any loss in its shape and size. The high frequency supplied to the piezo elements of the actuating toolholder generates a corresponding vibration on the tip of the tool between 20. Mechanical engg r syllabus free download as word doc.
Paul,department of mechanical engineering, iit kharagpur. It is known that the lattice distances between two atoms are of the order of 0. Page 2 the emerson laboratory what is the emerson laboratory. Ultrasonic machining is of particular interest for the cutting of nonconductive, brittle workpiece materials such as engineering ceramics. The abrasive particles are, therefore, hammered into the workpiece surface and cause chipping of fine particles from it. This paper presents an investigation of the effect of process parameters on micro rotary ultrasonic machining micro rum performance. Particularly suited for very hard andorbrittle materials such asgraphite, glass, carbide, and. It also includes micronanofinishing processes viz, abrasive flow finishing, magnetic abrasive finishing, etc. Match listi machining process with listii associated medium and select the correct answer using the codes. Design of horn for rotary ultrasonic machining using the finite. The rival processes considered in this report the three machining processes that have been investigated are 1.
Curriculum2016 c16 for diploma courses in andhra pradesh preamble the state board of technical education and training, andhra pradesh under the aegis of the department of te. Society of mechanical engineers isme2003 iit roorkee, uttranchal india. The ultrasonic machining usm process is normally employed for hard andor. Mechanical machining ultrasonic machining usm and waterjet machining wjm are typical examples of single action, mechanical non traditional machining processes. Produce simple joints using arc and gas welding processes. Part 2 deals with thermal machining processes for example, electric discharge machining, laser beam machining, electron beam machining, etc. Advanced manufacturing processes usb media storage type. In ultrasonic machining, a liquid filled with abrasive material flows through over the work piece, and the work tool vibrates against the abrasives. Traditional machining processes consist of turning, boring, drilling, reaming, threading, milling, shaping, planing, and broaching, as well as abrasive processes such as grinding, ultrasonic machining, lapping, and honing. Answers to the assignments with full explanation nptel. In addition, the effects of some machining parameters on the amount of the material removal are investigated by. Types of abrasive machining processes grinding honing lapping superfinishing polishing buffing abrasive water jet machining ultrasonic machining. The machining medium is solid grains suspended in an abrasive slurry in the former,while a fluid is employed in the wjm process. Principle of ultrasonic machining in the process of ultrasonic machining, material is removed by microchipping or erosion with abrasive particles.
Unconventional machining process need classification brief overview. Abrasive flow finishing aff and its modelling magnetorheological finishing mrf nptel. Schematic of ultrasonic machine tool usm is primarily targeted for the machining of hard and brittle materials dielectric or. Slurry of abrasive and water vibration frequency f 19 25 khz amplitude, a 10 50. Display skills to perform basic machining and sheet metal operations. Chemical milling sometimes called chem milling or contour machining or etching. Jun 03, 2014 the chemical machining processes include those wherein material removal is accomplished by a chemical reaction, sometimes assisted by electrical or thermal energy applications. Introduction to advanced machining processes and their classification ultrasonic machining and its modelling and analysis 2. Lecture notes institute of aeronautical engineering. Finish form machining must, therefore, be a major goal of an automated process 2. Ultrasonic machining is ultrasonic machining processes, as being developed and applied at ewi, consist of the.
May 06, 2017 on this channel you can get education and knowledge for general issues and topics. An example of the material removal rate mrr formula for an ultrasonic machining process is given by the following formula. Ultrasonic technology poised for advance into general. In the present paper, an experimental study of the ultrasonicbased depassivation process and its benefits related to an ecm proces are presented and discussed. Combining ultrasonic and conventional machining operations. Different processes used in nonconventional machining are described below. Principle of ultrasonic machining 1 this is the standard mechanism used in most of the universal ultrasonic machines 632014 hareesha n g, dept of aero engg, dsce 11 12. In the process of the ultrasonic machining, the machining efficiency is affected directly by material removal rate. The tool travels vertically or orthogonal to the surface of the part at amplitudes of 0. Working principles equipment used process parameters mrrvariation in techniques used applications. The process involves an abrasive slurry that runs between the tool and the work piece. Because ultrasonic machining is not broadly adopted by brazilian manufacturing industries, the first part of this paper was devoted to recall the principle of operation and the main features of this process. 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 20 khz with an amplitude of about 25.
Machining processes have existed for a long time but it was only after the scientific study of these processes which started some fifty years ago that major improvements in tool design, tool materials and machining techniques where brought about. This chapter presents usm and rotary ultrasonic machining rum, including definitions, machine elements, input variables and their effects, applications, and advantages and disadvantages. All aspects of mechanical, electrochemical and thermal processes are comprehensively covered. Material of workpiece removed due to erosion caused by electric spark. Introduction ultrasonic machining usm is the removal of hard and brittle materials using an axially oscillating tool at ultrasonic frequencies 1820 khz during that oscillation, the abrasive slurry of b4c or sic is continuously fed into the machining zone between a soft tool brass or steel and the workpiece. This group includes chemical milling, photochemical machining, and thermo chemical machining. However, when machining size is reduced to the submillimeter range, as the size of abrasive grains is in the micrometer range, machining efficiency of usm becomes low. Miyan ram 1709653 1 introduction ultrasonic machining usm is the removal of hard and brittle materials using an axially oscillating tool at ultrasonic frequencies 1820 khz during that oscillation, the abrasive slurry of b4c or sic is continuously fed into the machining zone between a soft tool brass or steel and the workpiece. Particularly suited for very hard andorbrittle materials such asgraphite, glass, carbide, and ceramics. Nontraditional machining, utilizing electrical, chemical, and.
Singh, balbir singh modern machining processes presents unconventional machining methods which are gradually commercial acceptance. Simply stated, it is an area where students, faculty, staff, and all other members of the cornell community. Micro ultrasonic machining micro usm, is one of the efficient material removal processes especially suitable for the micromachining of hard and brittle materials. The ultrasonic machining center is also a fully capable conventional machining center. Manufacturing processes i nptel online videos, courses.
This book is an attempt to consolidate the basic scientific studies in the machining area so that fundamental mechanics and other concepts. May 20, 2017 water jet machining wjm also called water jet cutting, is a nontraditional machining process in which highvelocity jet of water is used to remove materials from the surface of the workpiece. Ultrasonic machining, or strictly speaking the ultrasonic vibration machining, is a subtraction 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. Wallace says the typical use of this machine would be conventional metalcutting most of the time, with the ultrasonic head loaded into the spindle for the parts and operations benefitting most from this capability. Basics of ecm process electrochemical machining ecm for conductive. Non traditional machining jagadeesha t, assistant professor, med, national institute of technology, calicut ultrasonic machining definition. Week2 machine shopmilling and other machines batch i. Jun 10, 2017 electro chemical machining consists of following basic elements.
Micro ultrasonic machining musm is a method derived from conventional ultrasonic machining, in which a tool and free abrasives are used. A new nontraditional machining method using cavitation. Ultrasonic machining usm is a nontraditional mechanical machining process and can be used in many applications. Describe the basic mechanism of material removal in usm ii. Based on the up to date development of the ultrasonic machining usm technology, applications and development trends of the ultrasonic machining tool are described. Ultrasonic machining introduction ultrasonic machining is a nontraditionalmechanical means of uniform stock materialremoval processit is applicable to both conductive andnonconductive materials.
A comparative study on ultrasonic machining of hard and. It is employed to machine hard and brittle materials both electrically conductive and. Usm is best suited for hard, brittle materials, such as ceramics. Shantanu bhattacharya nptel coordinating institute. In the paper, the material structure deformation under abrasive impacting is simulated by the lsdyna3d software, and the stresses occurring are analyzed numerically. Request pdf design of horn for rotary ultrasonic machining using the finite.
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