Ultrasonic Machining (USM)

What does USM stand for?

Ultrasonic Machining.

What energy category does USM belong to?

Mechanical energy processes.

How does USM remove material?

A vibrating tool drives abrasive particles in a slurry against the workpiece, causing small chips to break away.

What are the approximate vibration conditions in USM?

About 0.075 mm amplitude and approximately 20,000 Hz frequency.

In what direction does the USM tool oscillate?

Perpendicular to the work surface.

How is the final cavity shape produced in USM?

The tool is slowly fed into the work so that its shape is reproduced in the part.

What is the USM slurry made of?

Water mixed with abrasive particles.

What is the typical abrasive concentration in USM slurry?

Approximately 20% to 60%.

Why must the USM slurry circulate continuously?

To bring fresh abrasive grains into the gap and wash away chips and worn abrasive particles.

Which materials are especially suitable for USM?

Hard, brittle materials such as ceramics, glass, and carbides.

Which metals can also be machined successfully using USM?

Stainless steel and titanium.

What tool materials are commonly used in USM?

Soft steel and stainless steel.

How do frequency and amplitude affect material removal rate in USM?

Increasing either frequency or amplitude increases the material removal rate.

What are two important performance measures in USM?

Surface finish and material removal rate.