How Ultrasonic Machining Works. In simple terms, UM combines two main elements: A tool of the desired end shape, and; A high-power sine wave generator + transducer induces the necessary ultrasonic frequency, 15-30 kHz. The target zone is flooded with hardened abrasive particles contained in a slurry. At Bullen, we use silicon carbide, aluminum ...

The experimental results showed that ultrasonic milling can reduce the milling force by 22%, and the chatter amplitude can be reduced by more than 25%. Based on this, Sun et al. studied the chatter problem during robotic ultrasonic-assisted machining immediately. A stability lobe diagram was obtained, and the accuracy of the established …

Ultrasonic vibration-assisted (UVA) cutting is an advanced technique to improve the machinability and productivity of difficult-to-machine materials. This paper aims to assess the cutting performance of ultrasonic vibration-assisted milling (UVAM) technique and conventional milling (CM) in side milling of Ti–6Al–4 V. Tool trajectory …

The objective of this paper will be to present a new physical model based on rotary ultrasonic milling which will help provide a better scientific understanding of the …

3.2 Ultrasound-assisted milling (UAM) The objective of this part of the report is to research the operation of milling when ultrasonic applied to the milling process. In this regard, a slot-milling experiment was conducted on a steel alloy workpiece. Various influential parameters, like cutting speed, depth of cut, feed rate, and ultrasonic ...

Also known as ultrasonic vibration machining, it's a manufacturing process that's used to remove material from a workpiece through the use of high-frequency vibrations combined with particles. An ultrasonic tool essentially creates many small vibrations that, over time, remove material from the workpiece with which it's used.

Titanium alloy is a typical difficult-to-cut material due to its high strength and high stiffness. To solve the problem of the low efficiency and poor surface quality in the milling of titanium alloy, this paper proposes a novel longitudinal-torsional ultrasonic vibration milling (LTUVM) process. An ultrasonic horn with spiral slots was designed to …

Furthermore, the ultrasonic function angle is defined, and the cutting layer thickness model, the dynamic milling force model and the dynamic differential equation under ultrasonic vibration are ...

The poor rigidity of large composite material components in the helicopter has an important impact on robotic milling stability. Based on the machining stability of robotic edge trimming process, a method for calculating the component overhang is proposed in this paper. Firstly, the stability model of robotic longitudinal-torsional ultrasonic milling …

Compared to conventional machining (CM), ultrasonic vibration-assisted machining (UVAM) with high-frequency and small-amplitude has exhibited good cutting …

Hence, it has great prospective to combine rotary ultrasonic milling with the non-mechanical process. This study focuses on the feasibility evaluation of the combined process of rotary ultrasonic milling and anodizing in the fabrication of hierarchical micro/nanostructures on titanium alloy. The principle of the combined process is shown …

Ultrasonic Machining. An ultrasonic machining head, consisting of the cutting tool (1), ultrasonic horn (2), and water-cooled transducer (4), developed by Isayev and Anokhin, …

2.1 Trajectory model of cutting edge in UVAM. The trajectory of the milling edge after ultrasonic vibration is applied to the tool is very different from conventional milling. The trajectory of the milling edge has a direct effect on the milling force, which ultimately affects the surface profile and surface quality after machining.

Furthermore, the ultrasonic function angle is defined, and the cutting layer thickness model, the dynamic milling force model, and the dynamic differential equation under ultrasonic vibration are ...

Rotary ultrasonic milling (RUM) is a compound machining technology, with an auxiliary axial ultrasonic vibration generated on the machine spindle. It has obvious advantages in machining hard and brittle materials compared with the conventional milling (CM) technology [25], [26], [27]. There are many types of research focus on rotary …

In Eq. (), (varphi) represents the instantaneous milling entry angle on the bottom edge of the milling tool edge = 2πnt/60.In ultrasonic vibration, the longitudinal vibration will cause the milling cutter to produce axial reciprocating motion relative to the workpiece, the 3D milling model is equivalent to the bevel cutting model; the schematic …

However, using ultrasonic-assisted milling method, the three stages were found in 0–5 min, 5–50 min, and 50–70 min, respectively, and edge collapse occurred after milling for 70 min. Compared to …

Ultrasonic milling is a non-traditional machining process that uses high-frequency vibrations to remove material from a workpiece. The ultrasonic waves are generated by a piezoelectric transducer that converts electrical energy into mechanical vibrations. This technology allows for precise and controlled cutting, even in complex and …

The ultrasonic milling and grinding reduces the particle size of the pigments uniformly so that a smooth texture is obtained. This is an important step since the texture of a lipstick is an essential quality mark and a grainy feel is undesired. Furthermore, the uniform particle size distribution is crucial to obtain tinting strength and in ...

Their experimental results showed that the assistance of axial ultrasonic vibration improves the milling process by reducing tool wear, surface roughness and burr height. The results also show that effect of ultrasonic vibration decreases with increase in rotational speed. Elhami et al. [25] studied the effect of machining parameters on cutting ...

The milling equipment used in this experiment was an ultrasonic-assisted machining machine (DMC SS-600), and the ultrasonic vibration frequency was 43.26 kHz. The three parts of the cutting force are measured using the …

2.1 Experimental device and testing process. A CNC machining center (HenFUX-HFM 700L) with both conventional milling and ultrasonic milling functions was used in this study. Figure 1 shows the processing device that was used for milling the samples. The machine tool spindle included a piezoelectric transducer, an ultrasonic …

It can reduce the milling vibration effectively and improve the quality of machined surface [25,26]. Zheng et al. [27][28][29] [30] proposed a robotic rotary ultrasonic machining technology to ...

The comprehensive analysis of the prediction models and experimental results revealed that ultrasonic vibrationassisted milling can reduce surface roughness by approximately 40-70% compared to ...

This study aims to investigate the effect of combined mechanical and ultrasonic milling on the size reduction of talc. Firstly, the talc sample was wet ground in a stirred media mill for five different times (30, 60, 90, 120, and 150 min), and the optimum result was subsequently achieved with treatment by ultrasonication. The effects of …

The minimum reduction in the milling force in ultrasonic-assisted milling along the x-, y-, and z-axes was 11.77%, 15.52%, and 17.66%, respectively, compared with that in conventional milling.

Ultrasonic machining is a specialized technology used for machining difficult-to-process materials such as hard brittle materials, composite materials, and challenging metal materials. It has significant potential for use in various industries, including aerospace, automotive, semiconductor, 3C, and medical.

Ultrasonic assisted milling (UAM) is one of the advancements in the area of conventional milling process. Literature suggests that superpositioning of ultrasonic …

The study aims to study the effect of ultrasonic vibration ball-end milling times on the surface integrity of the Inconel 718 workpiece. Milling experiments are conducted to compare the effects of ultrasonic vibration ball-end milling and conventional ball-end milling processes, with the same parameters but different ultrasonic vibration …