11 Facts About Ultrasonic machining

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.

Ultrasonic vibration machining is typically used on brittle materials as well as materials with a high hardness due to the microcracking mechanics.

The sonotrode removes material from the work piece by abrasion where it contacts it, so the result of Ultrasonic machining is to cut a perfect negative of the sonotrode's profile into the work piece.

Ultrasonic vibration machining allows extremely complex and non-uniform shapes to be cut into the workpiece with extremely high precision.

The surface finish of materials after Ultrasonic machining depends heavily on hardness and strength, with softer and weaker materials exhibiting smoother surface finishes.

Ultrasonic vibration machining physically operates by the mechanism of microchipping or erosion on the work piece's surface.

Rotary ultrasonic vibration machining is a relatively new manufacturing process that is still being extensively researched.

Ultrasonic machining is precise enough to be used in the creation of microelectromechanical system components such as micro-structured glass wafers.

Additionally, ultrasonic machining is capable of manufacturing fragile materials such as glass and non-conductive metals that can not be machined by alternative methods such as electrical discharge machining and electrochemical machining.

Ultrasonic machining is able to produce high-tolerance parts because there is no distortion of the worked material.

Note, rotary ultrasonic machining is efficient at drilling deep holes in ceramics because the absence of a slurry cutting fluid and the cutting tool is coated in harder diamond abrasives.