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. Plasma arc machining process, diagram, advantages and. 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. Technological improvement of machining processes can be achieved by combining different machining actions or phases to be used on the material being removed. As illustrated in figure 18, different type and size of cutters should be selected for achieving the. Ultrasonic enhancement of an electrochemical machining. Wjm can be used to cut softer materials like plastic, rubber or wood.
Ultrasonic machining introduction ultrasonic machining is a nontraditionalmechanical means of uniform stock materialremoval processit is applicable to both conductive andnonconductive materials. Design for environment, design for environment process, product architecture, rapid prototyping, product design manufacturing perspective. The ultrasonic machining center is also a fully capable conventional machining center. These high velocity abrasive particles remove metal by brittle fracture or erosion from work piece. Jun 07, 2018 abrasive jet machining project for mechanical engineering degree and diploma students. December 2729, 2010, iit kharagpur, india ictacem2010 paper. Mechanism analysis of ultrasonic machining based on finite.
Singh, balbir singh modern machining processes presents unconventional machining methods which are gradually commercial acceptance. In micro usm workpiece which is placed on the workpiece table vibrates at ultrasonic frequency 40 khz. A new nontraditional machining method using cavitation process. Index termscavitation machining, hydrodynamic, ultrasonic, abrasive particle. Paul,department of mechanical engineering, iit kharagpur. Unconventional machining process need classification brief overview. Nptel, online courses and certification, learn for free.
A mechanical conventional single cutting or ma action process can be combined with the respective machining phases of electrodischarge ed in electrodischarge machining edm or ecd in ecm. Ultrasonic machining,direct impact,abrasive grains,material removal rate. Plasmaarc machining pam employs a highvelocity jet of hightemperature gas to melt and displace material in its path. Schematic of ultrasonic machine tool usm is primarily targeted for the machining of hard and brittle materials dielectric or. An introduction to ndt common methods 3 section 2 visual and optical testing visual testing is the most widely used method of nondestructive testing ndt. Pdf process parameters of ultrasonic machining researchgate. 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. Manufacturing processes i nptel online videos, courses.
Usm is grouped under the mechanical group ntm processes. Ultrasonic machining usm is the removal of material by the abrading action of. Abrasives gas propulsion system supplies clean and dry air. Micro ultrasonic machining micro usm, is one of the efficient material removal processes especially suitable for the micromachining of hard and brittle materials. In the present paper, an experimental study of the ultrasonic based depassivation process and its benefits related to an ecm proces are presented and discussed. Introduction to nontraditional machining iit kanpur. Ultrasonic machining is a nontraditional machining process. Ultrasonic, abrasive jet abrasive water jet machining. In ultrasonic machining, the material is removed by.
Nptel video lectures, iit video lectures online, nptel youtube lectures, free video lectures, nptel online courses, youtube iit videos nptel courses. 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. The use of ultrasonic for machining processes of hard and brittle. Ultrasonic machining process usm video lecture by prof a. In this machining process a focus stream of abrasive particles are forces to impinge on work piece at high velocity. 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.
Download link is provided and students can download the anna university me6004 unconventional machining processes ump syllabus question bank lecture notes syllabus part a 2 marks with answers part b 16 marks question bank with answer, all the materials are listed below for the students to make use of it and score good maximum marks with our study materials. This chapter presents usm and rotary ultrasonic machining rum, including definitions, machine elements, input variables and their effects, applications, and advantages and disadvantages. Lecture series on manufacturing processes ii by prof. Unit ii mechanical energy based processes 10 abrasive jet machining water jet machining abrasive water jet machining ultrasonic machining. Usm is a versatile machining process as far as properties of materials are concerned. Particularly suited for very hard andorbrittle materials such asgraphite, glass, carbide, and ceramics. 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. Jun 03, 2014 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. Machining ultrasonic machining the industrial resource. Ultrasonic machining and electrical discharge machining d. 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.
Diesinker edm and wire cut electric discharge machining wedm 21. In the paper, the material structure deformation under abrasive impacting is simulated by the lsdyna3d software, and the stresses occurring are analyzed numerically. Called pam, this is a method of cutting metal with a. Even the more sophisticated methods require a visual test to be performed. Ultrasonic machining usm is the removal of material by the abrading action of gritloaded liquid slurry circulating between the workpiece and a. Ultrasonic machining is a mechanical type nontraditional machining process. 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. In order to cut harder materials like metals or granite, an abrasive material is. Apr 15, 20 ultrasonic machining introduction ultrasonic machining is a nontraditionalmechanical means of uniform stock materialremoval processit is applicable to both conductive andnonconductive materials. 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. Abrasive jet machining is a nontraditional machining process which is mostly used in machining of hardened metals. Oct 22, 2008 lecture series on manufacturing processes ii by prof. Slurry of abrasive and water vibration frequency f 19 25 khz amplitude, a 10 50. Abrasive jet machining project for mechanical engineering degree and diploma students.
During these processes abrasion on the work material is created by the flowing high velocity of abrasive particles or fluid. Study of parameters of ultrasonic machining ethesis. Study of ultrasonic machining by longitudinaltorsional. Ultrasonic machining usm and waterjet machining wjm are typical examples of single action, mechanical non traditional machining processes. Particularly suited for very hard andorbrittle materials such asgraphite, glass, carbide, and. We studied a new ultrasonic machining method using ultrasonic complex vibration caused by the longitudinal and torsional vibration. A new nontraditional machining method using cavitation. Basics of ecm process electrochemical machining ecm for conductive. How an abrasive jet machining works engineers academy.
Hydrodynamic cavitation machining hcm, and ultrasonic cavitation machining ucm, they will be introduced, and the parameters associated with them will be presented. The vibration exciter, a magnetostrictive transducer 1, is fixed to the body 2 of the acoustic head using the shoulder 3 and the thin walled cup 4. Called pam, this is a method of cutting metal with a plasmaarc, or tungsten inertgasarc, torch. It is also known as ultrasonic impact grinding is an operation that involves a vibrating tool fluctuating the ultrasonic frequencies in order to. Ultrasonic machining national institute of technology calicut. Ultrasonic technology poised for advance into general machining. Water jet machining working principle, advantages and. Ultrasonic enhancement of an electrochemical machining process. What is hybrid manufacturing and classification of hybrid.
Smart material, adaptive structures and intelligent mechanical systems iitk. Air, nitrogen and carbon dioxide to propel the abrasive particles. Design for environment, design for environment process, product architecture, rapid prototyping, product design. Gas may be supplied either from a compressor or a cylinder.
Metal casting is a labour intensive process automation. In the process of the ultrasonic machining, the machining efficiency is affected directly by material removal rate. Ultrasonic machining is also known as ultrasonic vibration machining. Plastics, microwave joining, hole making in polymer and polymer matrix composites. 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. Ultrasonic machining from the technology data exchange linked to trusted tde listed vendors. Nptel provides elearning through online web and video courses various streams. Manufacturing processes ii nptel online videos, courses. 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.
Learn for free, pay a small fee for exam and get a certificate. Answers to the assignments with full explanation nptel. Mar 29, 2017 abrasive jet machining is a nontraditional machining process which is mostly used in machining of hardened metals. The ultrasonic machining is a processing method using both the ultrasonic vibration of the tool horn and abrasive slurry. Gang milling gang milling is a horizontal milling operation that utilises three or more milling cutters grouped together for the milling of a complex surface in one pass. Ultrasonic machining usm is a nontraditional mechanical machining process and can be used in many applications. In the present paper, an experimental study of the ultrasonicbased depassivation process and its benefits related to an ecm proces are presented and discussed. Machining a material removal process in which a sharp cutting tool is used to mechanically cut away material so that the desired part geometry remains most common application. Mechanism, processes variants and applications of usm. All aspects of mechanical, electrochemical and thermal processes are comprehensively covered. Usm is abrasive machining method but laser beam machining is. Experimental study of micro ultrasonic machining process. They belong to mechanical group of nonconventional processes like ultrasonic machining.