Ultrasonic machining gained its place among hundreds of techniques used in the fabrication industry from its speed, versatility, and precision. This type of machining has been used in many areas and industries, including aerospace, automotive, medical and audio.
The ultrasonic machining process begins with the selection of the drill bit or tool suitable for the material being machined. The process also needs a specifically designed transducer to generate energy, and an ultrasonic generator to power the process. After providing the material to the machine, the drill bit or tool is sprayed with a coolant to reduce heat during the cutting process.
The sound energy generated by the transducer is transmitted to the drill bit, which, in turn,e creates small, uniform particles that are detached from the material during the cutting process. This process continuously removes material, reducing the need for follow up machining, ensuring high accuracy and a good surface finish without grinding.
The mechanical action of the cutting tool aids in making the process faster and more efficient. The ultrasonic machining process does not require a large amount of force, so it does not distort or damage the material being machined. This low force also prevents breakage of the drill bit and the material, eliminating the need for frequent sharpening.
Ultrasonic machining is considered a non-traditional machining method due to its lack of direct contact between the tool and the material being machined. Furthermore, the machining of hardened materials is much easier than traditional machining methods due to the reduced force and tool wear.
The benefits of ultrasonic machining include increased speed, high accuracy and precision, chip production at an extremely rapid rate, excellent surface finish, improved productivity, and flexibility during operation. Additionally, the machining process can be used on a variety of materials, including: titanium, stainless steel, copper alloys, aluminum, soft metals, and plastics.
The main disadvantage of ultrasonic machining is that it is limited to shallow depths. Ultrasonic machining can only reach depths of 10 to 12mm depending on the material being machined. The other limitation of ultrasonic machining is its expense. The equipment required for this process is expensive, compared to other machining techniques. This can be offset by the cost savings from decrease set up times and increased operator efficiency.
Overall, ultrasonic machining offers a fast, versatile, and precise solution to many custom machining needs. With its production flexibility and low need for tool maintenance and breakage, this process is becoming increasingly more popular among fabrication shops due to its cost savings and improved production capabilities.
