Ultrasonic machining also called ultrasonic vibration machining is a machining process in which, in the presence of abrasive particles, the material is removed from a part's surface by low amplitude and high-frequency vibration of a tool against the material surface. Let us have a deep insight into the pros and cons of ultrasonic machining in this article.
Advantages of ultrasonic machining :
- Ultrasonic machining can be used to drill circular or non-circular holes on very hard materials like stones, carbides, ceramics and other brittle materials.
- Machining of non-conducting materials like glass, ceramics and semi-precious stones easily.
- The cost of metal removal is low.
- As there is no heat generation in this process, there is no change in the physical properties of the job during machining.
- There are no residual stresses in the machined workpiece.
- This machining method produces highly accurate profiles and good surface finishes.
- The operation of the equipment is quite safe and noiseless.
- Free from burrs and distortions.
- Good surface finish and structural integrity.
Disadvantages of Ultrasonic Machining :
- The major limitation of the ultrasonic machining process is its comparatively low metal cutting rates.
- Power consumption is high.
- The depth of cylindrical holes is presently limited to 2.5 times the diameter of the tool.
- Wear of tool increases so sharp corners become rounded.
- The grain size and abrasive slurry are also the correct dimensions.
- Periodic replacement of slurry is necessary for efficient cutting operations.
- The choice of tool metal is one of the most important decisions making for optimization of metal removing and tool cost.
- Replacement of tool is required for accurate machining as the high wear rate of the tool results in poor dimensional accuracy.
- Initial machining and tooling costs are very high.
- This process is not suitable for heavy metal removal operations.
- Softer materials give much difficulty in machining.
- Limited sized cavities are produced by this machining process.
- Minimum depth of the hole is achieved.