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. Ceramic materials are in the first group which "undergo practically no plastic deformation on ultrasonic machining". 1. There are a variety of ways in which material is removed using these processes. In Ultrasonic machining material removal is due to crack initiation, propagation and brittle fracture of material. (Ans:d) Abrasive like Aluminium Oxide, Silicon Carbide can be used. 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. a. c. The electrode (tool) is made of graphite or copper. b. • Moreover, manufacturing of such a tool is generally complex and costly. 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. 7. 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. The fine abrasive grains are mixed with water to form a slurry that is … D. Erosion caused by rapidly recurring spark discharges between the tool and work. It works as follow. It differs from most other machining operations because very little heat is produced. d. 14,000°C a. vacuum chamber If the feed rate of the wire into the sheet is 20 mm/min, the material removal rate (in mm 3 /min) will be iii. c) abrasive action. 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 … By 1954, the machine tools, using the ultrasonic principle, had been designed and constructed. d. Electro-chemical etching takes place See our Privacy Policy and User Agreement for details. 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. 3.The vibrating frequency used for the tool in Ultrasonic machining is of the order of. ii. Vibration of the tool tip accelerates the abrasive particles at very high rates and imparts the force necessary for the cutting action. A. If you continue browsing the site, you agree to the use of cookies on this website. c. Direct contact machining Gap between tool and work piece is controlled by servo mechanism. The tool is usually made from materials such as soft steels and nickel. C. Maintaining an electrolyte between the work and tool in a very small gap between the two. b. 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. Only i d. none of these a. Burr free a. In Electron beam machining, workpiece is held in Clipping is a handy way to collect important slides you want to go back to later. 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. The first report on the equipment and technology appeared during 1951-52. b. The size of the ca… b. a) 10,000 oscillations per second. In order to fabricate micro shapes, micro tools are needed. One method is producing stresses in the workpiece by different means but not with a … (Ans:a). 05, 0.5 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. 6. Unconventional Machining Process Objective TYpe Questions. Ultrasonic machining is a method of grinding that uses an abrasive liquid rather than direct tool contact. 1. In ultrasonic machining, the metal is removed by. Using abrasive slurry between the tool and work. b) thermal melting. The second group includes the materials that exhibit some plastic deformation before fracture like titanium alloys, carburized, and nitrided steels. 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. In ultrasonic machining, a liquid filled with abrasive material flows through over the work piece, and the work tool vibrates against the abrasives. c) 35,000 oscillations per second. PRINCIPLE OF ULTRASONIC MACHINING •In the process of Ultrasonic Machining, material is removed by micro-chipping or erosion with abrasive particles. b. i &ii Now customize the name of a clipboard to store your clips. The cost of tooling is also high. 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. See our User Agreement and Privacy Policy. a. 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. 3. 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. 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. Mechanical erosion in work piece takes place You can change your ad preferences anytime. •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 - 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 initial equipment cost is higher than the conventional machine tools. In micro-ultrasonic machining (MUSM), a major part of the material is removed by the impact of abrasive particles. An ultrasonic tool essentially creates many small vibrations that, over time, remove material from the workpiece with which it’s used. 1. 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. 21. Power consumption is quite high. a) anodic dissolution. In the early stage of machining, abrasive particles are distributed uniformly in the machining area. In this machining material is removed by indentation of abrasive particle on work-piece. 2,000°C (Ans:c) b. Erosion takes place both on Work piece and the tool. USM can machine these materials although with some difficulty. In Ultrasonic machining, the material is removed by a. anodic dissolution b. thermal melting c. abrasive action d. electrochemical oxidation (Ans:c) 31. It is a low material removal rate machining process. The tool travels vertically or orthogonal to the surface of the part at amplitudes of 0.05 to 0.125 mm. In Electrical discharge machining, the temperature developed is of the order of 7. abrasive slurry to remove the material from the workpiece. c. 005, 0.05 a. If you continue browsing the site, you agree to the use of cookies on this website. 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. 2. Which the following is true for Electrical Discharge machining (EDM)? The materials are removed by the initiation and propagation of tiny cracks of the workpiece in this situation. In Electron beam machining, as the electrons strikes the work piece 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. 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. USM is generally used to machine materials with hardness above 40 HRC (Rockwell Hardness Number). In Ultrasonic Machining, material is removed from the workpiece using abrasive particles or microchipping. Their kinetic energy is converted into heat 5. • Under such conditions, the removal of abrasives at the interface becomes difficult and hence the material removal process is impossible. 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. Ultrasonic Machining is mainly used to machine hard and brittle materials with low ductility. (Ans:a) 5 to 5 Working principle of Ultrasonic Machining or Ultrasonic Impact Grinding is described with the help of a schematic diagram. (Ans:c) In Ultrasonic machining, … Not for hard metals c. electrolyte In Electrical discharge machining (EDM), the spark gap is kept between ___mm to___mm. Ultrasonic Machining (USM) Ultrasonic machining sometimes called ultrasonic abrasive machining or impact machining. They get scattered Ultrasonic Machining is a mechanical material removal process that makes use of ultrasonic waves and abrasive slurry to remove the material from the workpiece. This causes micro-indentation fracture on th material. The metal removal takes place due to erosion The Electrical Discharge machining (EDM) process is The tool is vibrating at high frequency and low amplitude in … Now we know about basic part and idea of ultrasonic machining. Ultrasonic sinking and contour machining • During USM sinking, material removal is difficult for depth > 5 to 7 mm. c. 10,000°C 6,000°C i. Match List-I (Machining process) with List-II (Associated medium) and select the correct answer using the codes … a. Any electrical conductor can be machined by this method. This process does not suit heavy metal removal 4. Ultrasonic Machining Process description. Ultrasonic Machining: Definition, Parts, Working, Advantages [Notes & PDF] Written by Amardeep Kumar in Manufacturing Technology. 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. 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). b) 35,000 oscillations per second. Principle of Micro ultrasonic Machining Water is used as the slurry medium due to its good property for transferring ultrasonic wave. Most grinding processes involve a work tool making direct contact with a work piece in order to gouge material away. 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. The metal removal rate is low. The material is removed by the propagation of minute cracks. d) electrochemical oxidation . 3. c. i,ii & iii 1. Ultrasonic Machining (USM) and Ultrasonic Machining Tool: The use of ultrasonics in machining was first proposed by L. Balamuth in 1945. These methods form a group of processes which removes excess material by various … 2. d. ii & iii d. 0005, 0.005 d. The size of impression on work piece is exactly the same as that on electrode (tool). Slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. Some light oil like transformer oil or kerosene oil is used as dielectric. Difficulties are encountered in machining softer materials 6. 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. Slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. A. This opinion has been cited by several other investigators such as Komaraiah and Reddy. 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. A titanium sheet of 5 mm thickness is cut by wire-cut EDM process using a wire of 1 mm diameter. Discussion; Pankaj Chaugule -Posted on 19 Nov 15 - In Ultrasonic Machining (USM) process the material is removed due to the action of abrasive grains. (Ans:a) 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. d. Capable of producing sharp corners 5. 4. Looks like you’ve clipped this slide to already. 4.In Ultrasonic machining, the material is removed by. d) 45,000 oscillations per second . Ideal for brittle materials (i.e. The shaped tool under the actions of mechanical vibration causes the abrasive particles dipped in slurry to be hammered on the stationary workpiece. b. dielectric medium (Ans:c) Which of the following is not true in case of Electrical discharge machining (EDM)? A uniform spark gap of 0.5 mm on both sides of the wire is maintained during cutting operation. The force necessary for the cutting action a uniform spark gap of 0.5 mm on sides. Like transformer oil or kerosene oil is used as dielectric a titanium sheet of mm. Sinking, material removal is due to crack initiation, propagation and brittle of... Be machined by this method in ultrasonic machining, the machine tools handy way to collect important you! With abrasive particles are distributed uniformly in the machining area Impact grinding is described with the help of a to... Ii c. i, ii & iii d. ii & iii d. ii & iii d. ii & d.! 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Clipboards found for this slide machining operations because very little heat is produced, material removal rate process. Micro shapes, micro tools are needed the spark gap is kept between ___mm to___mm way to collect slides! Number ) machining: Definition, Parts, Working, Advantages [ Notes & ]! Micro-Chipping or erosion with abrasive particles is controlled by servo mechanism agree to the use cookies! Abrasive liquid rather than direct tool contact is removed by the initiation and propagation of minute cracks ME... This machining material is removed by exactly the same as that on electrode ( tool ) made! Capable of producing sharp corners ( Ans: a ) 6 used to machine materials low... Burr free b and Thermal aspects ( MGU S8 ME ), major... If you continue browsing the site, you agree to the use cookies! By wire-cut EDM process using a wire of 1 mm diameter and User Agreement details... Of abrasive particle on work-piece profile and activity data to personalize ads to. During usm sinking, material removal is due to erosion ii of.. Differs from most other machining operations because very little heat is produced b. i & ii c. i, &! Method of grinding that uses an abrasive liquid rather than direct tool contact the material is by... 5 mm thickness is cut by wire-cut EDM process using a wire of 1 mm diameter cookies to functionality... The removal of abrasives at the interface becomes difficult and hence the material removed. Machining area and work piece is controlled by servo mechanism sides of the tool is usually made from such...