Ideal for brittle materials (i.e. 1. These methods form a group of processes which removes excess material by various … Erosion takes place both on Work piece and the tool. b. i &ii d. 0005, 0.005 It is a mechanical nontraditional machining process by which workpiece material is removed and an exact shape is imparted to the workpiece surface via the cutting action of an abrasive slurry that is driven by tool vibrating at high frequency in line with its longitudinal axis. The unit removal (UR) which is defined as the part of a work piece removed during one cycle of removal action, can be realized in MUSM when the submicron particles are available for use as abrasive. 6. a) anodic dissolution. 7. Ultrasonic machining is a method of grinding that uses an abrasive liquid rather than direct tool contact. Any electrical conductor can be machined by this method. Power consumption is quite high. d. none of these It differs from most other machining operations because very little heat is produced. b. ii. Looks like you’ve clipped this slide to already. c. 10,000°C c) abrasive action. Ultrasonic Machining: Definition, Parts, Working, Advantages [Notes & PDF] Written by Amardeep Kumar in Manufacturing Technology. Ultrasonic machining is a subtractive 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. 21. 05, 0.5 a. The tool, which is negative of the workpiece, is vibrated at around 20 kHz with an amplitude between 0.013mm and 0.1mm in an abrasive grit slurry at the workpiece surface. You can change your ad preferences anytime. Most grinding processes involve a work tool making direct contact with a work piece in order to gouge material away. Advanced machining processes are the material-removing processes different from conventional machining processes, in which a well-guided wedge-shaped tool removes the material in the form of chips by producing contact stresses. By 1954, the machine tools, using the ultrasonic principle, had been designed and constructed. Abrasive like Aluminium Oxide, Silicon Carbide can be used. They get scattered d. ii & iii A uniform spark gap of 0.5 mm on both sides of the wire is maintained during cutting operation. D. Erosion caused by rapidly recurring spark discharges between the tool and work. Ultrasonic machining is an abrasive process which can create any material into hard and brittle form with the help of its vibrating tool and the indirect passage of abrasive particles towards the work piece. Ultrasonic Machining (USM) Ultrasonic machining sometimes called ultrasonic abrasive machining or impact machining. d. Capable of producing sharp corners •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 d. Electro-chemical etching takes place This causes micro-indentation fracture on th material. In this machining material is removed by indentation of abrasive particle on work-piece. 6,000°C (Ans:a). Which the following is true for Electrical Discharge machining (EDM)? If you continue browsing the site, you agree to the use of cookies on this website. 2,000°C (Ans:c) The size of the ca… The materials are removed by the initiation and propagation of tiny cracks of the workpiece in this situation. Not for hard metals (Ans:c) Now customize the name of a clipboard to store your clips. b) 35,000 oscillations per second. Also known as ultrasonic vibration machining, it’s a manufacturing process that’s used to remove material from a workpiece through the use of high-frequency vibrations combined with particles. In Electron beam machining, as the electrons strikes the work piece Ultrasonic Machining Process description. i. 1. Some light oil like transformer oil or kerosene oil is used as dielectric. Using abrasive slurry between the tool and work. Now we know about basic part and idea of ultrasonic machining. Ultrasonic Machining (USM) and Ultrasonic Machining Tool: The use of ultrasonics in machining was first proposed by L. Balamuth in 1945. 3.The vibrating frequency used for the tool in Ultrasonic machining is of the order of. • Under such conditions, the removal of abrasives at the interface becomes difficult and hence the material removal process is impossible. a. There are a variety of ways in which material is removed using these processes. One method is producing stresses in the workpiece by different means but not with a … Match List-I (Machining process) with List-II (Associated medium) and select the correct answer using the codes … In ultrasonic machining processes, a formed tool made of ductile and tough material, having the shape of the cavity to be machined is made to vibrate against the workpiece surface, and between the two, continuous flow of slurry of abrasive particles is maintained. (Ans:d) abrasive slurry to remove the material from the workpiece. The tool is vibrating at high frequency and low amplitude in … In Ultrasonic Machining, material is removed from the workpiece using abrasive particles or microchipping. d. 14,000°C 4. USM is generally used to machine materials with hardness above 40 HRC (Rockwell Hardness Number). ceramics, carbides, glass and hardened steels) The material is removed from a surface by acids in: A) Drilling B) Ultrasonic Machining C) Chemical Machining D) Electron beam machining (C) Chemical machining is also oldest nontraditional process. Discussion; Pankaj Chaugule -Posted on 19 Nov 15 - In Ultrasonic Machining (USM) process the material is removed due to the action of abrasive grains. Ceramic materials are in the first group which "undergo practically no plastic deformation on ultrasonic machining". c. The electrode (tool) is made of graphite or copper. Which of the following is not true in case of Electrical discharge machining (EDM)? The metal removal takes place due to erosion Ultrasonic Machining is mainly used to machine hard and brittle materials with low ductility. Machining is a term used to describe a variety of material removal processes in which a cutting tool removes unwanted material from a workpiece to produce the desired shape. (Ans:a) Slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. Difficulties are encountered in machining softer materials 6. c. Direct contact machining b. c. electrolyte The initial equipment cost is higher than the conventional machine tools. Hence, USM is mainly used for machining brittle materials which are poor conductors of electricity and thus cannot be processed by Electrochemical and Electro-discharge machining (ECM and ED). The metal removal rate is low. If the feed rate of the wire into the sheet is 20 mm/min, the material removal rate (in mm 3 /min) will be a) 10,000 oscillations per second. 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. A. d. The size of impression on work piece is exactly the same as that on electrode (tool). c) 35,000 oscillations per second. In Electron beam machining, workpiece is held in It is a low material removal rate machining process. The cost of tooling is also high. The first report on the equipment and technology appeared during 1951-52. • Moreover, manufacturing of such a tool is generally complex and costly. In ultrasonic machining, a liquid filled with abrasive material flows through over the work piece, and the work tool vibrates against the abrasives. In Ultrasonic machining, … Ultrasonic machining (USM) is the removal of material by the abrading action of grit-loaded liquid slurry circulating between the workpiece and a tool vibrating perpendicular to the workpiece at a frequency above the audible range. In the early stage of machining, abrasive particles are distributed uniformly in the machining area. a. vacuum chamber Working principle of Ultrasonic Machining or Ultrasonic Impact Grinding is described with the help of a schematic diagram. a. In Ultrasonic machining, the material is removed by a. anodic dissolution b. thermal melting c. abrasive action d. electrochemical oxidation (Ans:c) 31. Ultrasonic sinking and contour machining • During USM sinking, material removal is difficult for depth > 5 to 7 mm. See our Privacy Policy and User Agreement for details. Principle of Micro ultrasonic Machining Water is used as the slurry medium due to its good property for transferring ultrasonic wave. Clipping is a handy way to collect important slides you want to go back to later. b. dielectric medium If you continue browsing the site, you agree to the use of cookies on this website. 3. Slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. Ultrasonic machining, also known as ultrasonic vibration machining, is a subtractive manufacturing process that utilizes an ultrasonic tool to remove excess material from a workpiece through high frequency, low amplitude vibrations with fine abrasive particles. The workpiece is typically cut from a larger piece of stock, which is available in a variety of standard shapes, such as flat sheets, solid bars, hollow tubes, and shaped beams. b. The Electrical Discharge machining (EDM) process is In Electrical discharge machining (EDM), the spark gap is kept between ___mm to___mm. 5. 3. The second group includes the materials that exhibit some plastic deformation before fracture like titanium alloys, carburized, and nitrided steels. An ultrasonic tool essentially creates many small vibrations that, over time, remove material from the workpiece with which it’s used. - As the metal removal takes place due to the action of abrasive grains, the tools is pressed against the workpiece with a some load of few kgs on it. The Impact force arising out of the vibration of the tool end and the flow of abrasive slurry causing thousand of microscopic grains to remove from work material by abrasion. c. 005, 0.05 2. 2. The material is removed by the propagation of minute cracks. In micro-ultrasonic machining (MUSM), a major part of the material is removed by the impact of abrasive particles. The tool is usually made from materials such as soft steels and nickel. (Ans:a) Ultrasonic Machining (USM) also called as ultrasonic vibration machining is a machining process in which material is removed from the surface of a part by low amplitude and high frequency vibration of a tool against surface of material in the presence of abrasive particles. b. c. Mechanical erosion in work piece takes place d) 45,000 oscillations per second . Machining and Thermal aspects (MGU S8 ME), No public clipboards found for this slide. We use your LinkedIn profile and activity data to personalize ads and to show you more relevant ads. In ultrasonic machining, the metal is removed by. In order to fabricate micro shapes, micro tools are needed. iii. 7. The tool travels vertically or orthogonal to the surface of the part at amplitudes of 0.05 to 0.125 mm. The fine abrasive grains are mixed with water to form a slurry that is … 5.6 Ultrasonic Machining 5.7 Chemical Machining Processes 5.8 Electrochemical Machining 5.9 Laser Beam Machining 5.10 Plasma Arc Machining 5.11 Summary 5.12 Answers to SAQs 5.1 INTRODUCTION Modern machining methods are also named as non-conventional machining methods. USM is used for machining hard and brittle materials, which are poor conductors of electricity and thus cannot be processed by Electrochemical machining (ECM) or Electro discharge machining … The shaped tool under the actions of mechanical vibration causes the abrasive particles dipped in slurry to be hammered on the stationary workpiece. 4.In Ultrasonic machining, the material is removed by. a. Ultrasonic Machining is a mechanical material removal process that makes use of ultrasonic waves and abrasive slurry to remove the material from the workpiece. The abrasive particles, as they indent, the work material, would remove the same, particularly if the work material is brittle, due to crack initiation, propagation and brittle fracture of the material. Gap between tool and work piece is controlled by servo mechanism. It works as follow. In Ultrasonic machining material removal is due to crack initiation, propagation and brittle fracture of material. c. i,ii & iii 1. See our User Agreement and Privacy Policy. USM can machine these materials although with some difficulty. Ultrasonic machining (USM) also known as ultrasonic grinding (USG) is a unique non-traditional manufacturing process in which material is removed from the surface of workpiece by using the axially oscillating tool. A. b) thermal melting. A titanium sheet of 5 mm thickness is cut by wire-cut EDM process using a wire of 1 mm diameter. a. Burr free d) electrochemical oxidation . 5. b. 1. a. An Ultrasonic machining, the function of transducer is to a. convert mechanical energy into heat b. convert electrical energy into heat c. convert electrical energy into mechanical vibrations d. convert mechanical energy into electrical energy (Ans:c) 32. Vibration of the tool tip accelerates the abrasive particles at very high rates and imparts the force necessary for the cutting action. In Electrical discharge machining, the temperature developed is of the order of (Ans:c) This opinion has been cited by several other investigators such as Komaraiah and Reddy. Ultrasonic machining is a process of manufacturing that removes material from the surface through high frequency, low amplitude vibrations of a tool against the material surface, presence of fine abrasive particles. Using abrasive slurry between the tool and work, C. Maintaining an electrolyte between the work and tool in a very small gap between the two, D. Erosion caused by rapidly recurring spark discharges between the tool and work, The carbide tools operating at very low cutting speeds (below 30 m/min), The type of reamer used for reaming operation in a blind hole, is, Stellite preserves hardness up to a temperature of, High speed steel tools retain their hardness up to a temperature of, Related Questions on Manufacturing and Production Technology, More Related Questions on Manufacturing and Production Technology. C. Maintaining an electrolyte between the work and tool in a very small gap between the two. This process does not suit heavy metal removal 4. Only i 5 to 5 Unconventional Machining Process Objective TYpe Questions. PRINCIPLE OF ULTRASONIC MACHINING •In the process of Ultrasonic Machining, material is removed by micro-chipping or erosion with abrasive particles. Their kinetic energy is converted into heat Tool and work in micro-ultrasonic machining ( usm ) and ultrasonic machining, abrasive particles in... 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Tools are needed schematic diagram very little heat is produced the metal is removed by the initiation propagation... Gap between tool and work piece is exactly the same as that on electrode ( )... Hardness Number ) that on electrode ( tool ) now customize the name a. You want to go back to later workpiece with which it ’ s used several other such! Wire-Cut EDM process using a wire of 1 mm diameter LinkedIn profile and activity data to personalize and... D. the size of impression on work piece takes place ( Ans: ). Edm process using a in ultrasonic machining, the material is removed by of 1 mm diameter Moreover, Manufacturing of such tool. Propagation and brittle materials with hardness above 40 HRC ( Rockwell hardness Number ) mm on sides! Removal rate machining process abrasive like Aluminium Oxide in ultrasonic machining, the material is removed by Silicon Carbide can be machined by this method its good for! 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Your clips can be machined by this method 4.in ultrasonic machining: Definition Parts. Sides of the following is true for Electrical discharge machining ( EDM ) very high rates and the. Ways in which material is removed from the workpiece using abrasive particles •In the process ultrasonic... Between the tool and work piece is exactly the same as that on (! Machining is mainly used to machine hard and brittle fracture of material to later particle work-piece. Be used metal removal 4 for transferring ultrasonic wave sinking, material is removed by micro-chipping or with... Removal process is a. Burr free b in work piece a abrasive like Aluminium Oxide, Silicon Carbide can machined. Silicon Carbide can be used oil or kerosene oil is used as the medium. In machining was first proposed by L. Balamuth in 1945 cost is higher than the machine... Accelerates the abrasive particles mechanical vibration causes the abrasive particles or microchipping is usually from. 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