Fine Finished Ultrasonic Machining Process For Ceramic Or Glass Drilling Or Milling
Considerable problems still exist in the fabrication of hard and brittle materials including ceramics and glass. Their superior physical and mechanical properties lead to long machining cycle and high production cost. Ultrasonic machining (USM) using loose abrasive particles suspended in a liquid slurry for material removal is consdidered an effective method for manufacturing these materials.
smoothed particle hydrodynamics (SPH)
hard and brittle materials
material removal mechanism
The time spent on ultrasonic machine entirely depends on the frequency of the vibrating tool. It also depends on the size of grains of the abrasive slurry, the rigidity and the viscosity as well. The grains used in the abrasive fluid are usually boron carbide or silicon carbide as they are rigid than others. The used abrasive can be carried away easily if the viscosity of the slurry fluid is less.
Now we know about basic part and idea of ultrasonic machining. In this machining material is removed by indentation of abrasive particle on work-piece. It works as follow.
First the low frequency electric current passes through electric supply. This low frequency current converts into high frequency current through some electrical equipment.
This high frequency current passes through transducer. The transducer converts this high frequency electric single into high frequency mechanical vibration.
This mechanical vibration passes through booster. The booster amplify this high frequency vibration and send to horn.
Horn which is also known as tool holder, transfer this amplified vibration to tool which makes tool vibrate at ultrasonic frequency.
As the tool vibrates, it makes abrasive particle to vibrate at this high frequency. This abrasive particle strikes to the work piece and remove metal form it.
3000 - 10000 r/min
Step or continuous
Working Time Control
Digital Generator, auto-tuning
Resonance point amplitude
10um or more
mill head Φ2-Φ13; disk cutter Φ50; dilling head Φ2-Φ6
Length of cable
3M or Customized
Machined all sorts of hard materials
Produces fine finished and structured results
Produces less heat
Various hole cut shapes due to vibratory motion of the tool
Best choice for working with hard materials such as ceramic matrix composites, ruby, piezo-ceramics, glass, ceramics, Quartz, ferrite, diamonds, technical ceramics, alumina, PCD, sapphire, CVD silicon carbide and similar ones.