What is Ultrasonic-assisted Machining? | Hantop Intelligence Tech. 2024/11/22 What is Ultrasonic-assisted Machining? | Hantop Intelligence Tech. The Working Principle of Ultrasonic-assisted Machining Ultrasonic-assisted Machining is a non-conventional, subtractive manufacturing process that utilizes the power of high-frequency vibraiton to remove material from workpiece. The range of ultrasonic vibration is typically over 20kHz (20,000 oscillations per second), which may be recognized as a silent process since the human ear cannot hear such high frequency. Generally, the ultrasonic power is transmitted via a transducer to the cutting tool, providing the tool with high frequency micro-vibration to facilitate in the milling, drilling, and grinding process. Ultrasonic-assisted machining is mostly used in the machining of advanced materials, which shows most benefits for hard-and-brittle and hard-to-cut materials, such as technical ceramics (Al2O3 / Aluminum Oxide, ZrO2 / zirconium dioxide, SiC / silicon carbide, quartz), optical glass, tungsten carbide, stainless steel, hardened steel, heat-resistant alloy (Ti-6Al-4V / titanium alloy, Inconel 718 / nickel alloy), etc. (Figure 1. rotary ultrasonic machining working principle for material removal, source: Precise Drilling of Holes in Alumina Ceramic (Al2O3) by Rotary Ultrasonic Drilling and its Parameter Optimization using MOGA-II) The high frequency micro-vibration works as a continuous series of hammering action that creates micro-cracks on the workpiece to help with material removal. The surface of the workpiece receives constant strikes from the tool which then builds up stress within the material to a certain point that forms micro-cracks. These micro-cracks allow the material to be easily removed from the workpiece. Therefore, ultrasonic-assisted machining is often used in the machining of micro-features, such as micro-holes (learn more on Ultrasonic-assisted Micro-Drilling of Silicon Carbide), drilling small and deep holes (learn more on Ultrasonic-assisted Deep Hole Drilling of AISI-1045 Carbon Steel), milling tiny internal threads (learn more on Ultrasonic-assisted M2 Internal Threading of Aluminum Oxide), or milling slots with high aspect ratio (learn more on Ultrasonic-assisted Full Slotting of AISI-4140 Alloy Steel). (Figure 2. HIT ultrasonic-assisted machining module serves to provide optimized machining process as a solution to the machining of advanced materials) Unique, Cutting-edge Technology of HIT Ultrasonic-assisted Machining Module HIT Ultrasonic-assisted Machining Module: Product Information [One Set of HIT Ultrasonic Machining Module] (Figure 3. HIT ultrasonic-assisted machining module product series collection) One set of HIT Ultrasonic-assisted Machining Module contains: a) an ultrasonic driver b) an ultrasonic toolholder (HBT, HSK, CAT series) c) an ultrasonic power transmitter d) an external control panel. a) Ultrasonic Driver - It is used to generate ultrasonic power and automatically detect proper frequency of vibration for the cutting tools. Customer may adjust the ultrasonic oscillation amplitude with the power level percentage, depending on the target machining material. (Figure 4. HIT ultrasonic-assisted machining module - ultrasonic driver) b) Ultrasonic Toolholder - HIT provides the most common specifications: HBT, HSK, and CAT series of toolholders, which work compatibly well with the majority of spindle types in CNC machining centers. (Figure 5. HIT ultrasonic-assisted machining module - ultrasonic toolholders) c) Ultrasonic Power Transmitter - It will be installed right beside the ultrasonic toolholder to transmit ultrasonic power to the toolholder. There will be a 0.5mm gap in between (the "non-contact" ultrasonic power transmission technology). (Figure 6. HIT ultrasonic-assisted machining module - ultrasonic power transmitter) (Figure 7. actual machining process by using HIT ultrasonic-assisted machining module) d) External Control Panel - It has the same interface as the ultrasonic driver. Machinists can use this panel to control the driver while the driver being installed inside the control box of the machine tool. (Figure 8. HIT ultrasonic-assisted machining module - external control panel) [Schematic Ullustration of Machine Integration] The following shows an illustration of the module and machine integration. (Figure 9. the installation and machine integration of HIT ultrasonic-assisted machining module) Here is a close-up illustration of the installation of ultrasonic power transmitter and ultrasonic toolholder. (Figure 10. the installing position of HIT ultrasonic toolholder and power transmitter with power transmitter jig) The Unique Design in HIT Ultrasonic Technology [Non-contact Ultrasonic Power Transmission] The method or device for transmitting ultrasonic power from the velocity transformer (or transducer) to the cutting tool varies from brand to brand. HIT Ultrasonic Toolholder implements the unique "non-contact (wireless) ultrasonic power transmission" technology, embedded inside with piezoelectric elements that help generate high frequency (20~32kHz) micro-vibration on the cutting tool. (Figure 11. the unique non-contact / wireless ultrasonic power transmission technology developed by HIT) There is a 0.5mm air gap between the ultrasonic power transmitter and the ultrasonic toolholder. This design obviates the need for regular replacement of carbon brushes and conductive slip rings in traditional ultrasonic machining products, which not only adding to the production costs but also limitting the increase of rotation speed. [Automatic Frequency Detection & Flexible Oscillation Amplitude Adjustment] The ultrasonic driver not only works to generate ultrasonic power (output) but also has the capability to detect and search for the proper frequency of the cutting tool (input) by automatic frequency-scan and frequency-lock. Different cutting tools have their corresponding frequency of vibration due to different geometric shapes and tool shank materials. The ultrasonic driver functions to constantly locate the proper frequency for the tool during the machining process, ensuring a stable output-input mutual interaction. (Figure 12. the monitor shows the corresponding frequency for the cutting tool detected by HIT ultrasonic driver) Customer can alter the ultrasonic oscillation amplitude by adjusting the Power Level knob on the driver (from 0% to 100%). It controls the intensity of ultrasonic oscillation in the axial direction. The intensity of the vibration varies with different targeted machining materials; for instance, the power level is usually set to 80-100% while machining hardened steels or heat-resistant alloys, which are in need of stronger striking force to assist with the cutting. (Figure 13. the ultrasonic oscillation amplitude can be adjusted by using the Power Level knob on the driver) [Easy Installation of Module System] This technology, packaged in a module system instead of whole machine, provides easy installation and integration with current CNC machines. The module can be seen as an upgraded program for CNC machines with a more flexible use of space, lower energy consumption, and much lower investment cost. Advantages of HIT Ultrasonic-assisted Machining Module The following illustrates the three main aspects that are mostly recognized as benefits derived from HIT ultrasonic-assisted machining process. (Usually one or two aspects stand out more than the other based on different machining process and purpose.) Higher Machining Efficiency As previously mentioned, ultrasonic-assisted machining operates by the mechanism of constantly striking the workpiece with high frequency micro-vibration that creates micro-scale cracks within the material. The micro-cracks allow the material to easily break off from the workpiece, and thus help enhance MRR (Material Removal Rate). The more material to be removed within the same amount of time indicates less total process time required, which brings higher machining efficiency. Longer Tool Life In conventional machining, it usually generates high cutting force and cutting heat when dealing with advanced materials, especially when it comes to high hardness materials or specific material properties that creates long, stringy cutting chips. Workpieces made of advanced materials often have strict standards or demands on its quality, which may require specialized or high-end cutting tools. High cutting force / heat can take a toll on the tool life and increase the production cost. With the application of HIT ultrasonic-assisted machining technology, the micro-vibration in axial (Z-axis) direction allows the cutting tool to lift from the workpiece, creating intermittent contact during the machining process. This brings better inflow of cutting fluid, enabling easier removal of cutting chips and cutting heat. Along with better material removal, it helps reduce the cutting force. The lowered cutting force and cutting heat consequently contribute to more stable and longer tool life. (Figure 14. with HIT ultrasonic, the formation of cutting chips is different with much smaller size compared to that without ultrasonic) (Figure 15. with HIT ultrasonic, it brings better ceramic particle flushing which greatly reduces tool wear) Better Workpiece Quality In the machining of advanced materials, workpiece quality (e.g. micro-hole quality or surface quality) is highly valued and mostly viewed as the critical determining factor in customer placing order. The most distinguished benefit of ultrasonic technology can be seen in the drilling hole quality. With the lowered cutting force, size of edge-cracks can be greatly reduced especially when drilling micro-holes on brittle materials. (Figure 16. with HIT ultrasonic, the size of edge-cracks around exit holes is greatly reduced in micro-drilling of glass material) Another notable advantage is the improvement in surface quality in terms of lower surface roughness and the mitigation of tool marks. The lowered cutting force / heat reduces tool wear and consequently helps moderate the friction between cutting tool and workpiece. (Figure 17. with HIT ultrasonic, the surface roughness is reduced with mitigating tool marks) On the premise of maintaining great workpiece quality and stable tool life, the machining parameters can be further optimized to achieve even higher machining efficiency. All things considered, rather than playing magic tricks, HIT Ultrasonic-assisted Machining Module offers an optimized solution for the machining process of advanced materials, aiming to provide cutting-edge expertise in upgraded process. Successful Case Studies of HIT Ultrasonic-assisted Machining of Advanced-Material Aluminum Oxide (Al2O3) Ceramic: G81 Micro-Drilling 🔸 10x HIGHER Machining Efficiency 🕑 🔸 5x LONGER Tool Life 💰 Silicon Carbide (SiC) Ceramic: (Helical) Circular Ramping 🔸 72% BETTER Surface Quality ✨ 🔸 Better Particle Flushing 💰 Quartz Glass: Side Grinding with Ultrasonic Grinding Wheel Toolholder 🔸 2x HIGHER Machining Efficiency 🕑 🔸 3x HIGHER Material Removal Rate 🕑 🔸 1.5x BETTER Workpiece Quality ✨ Nickel Alloy (Inconel 718): Keyway Side Milling 🔸 80% HIGHER Machining Efficiency 🕑 🔸 90% BETTER Surface Quality ✨ 🔸 3x LONGER Tool Life 💰 Tungsten Carbide: (Slot) Trochoidal Milling 🔸 2x BETTER Surface Quality ✨ 🔸 2x LONGER Tool Life 💰 AISI-4140 Alloy Steel: Full Slotting 🔸 2.5x BETTER Surface Quality ✨ 🔸 300% LONGER Tool Life 💰 🔎 Find out more Case Studies on Ultrasonic Machining Technology 📺 Check out Videos on Ultrasonic-assisted Machining Process - Hantop Intelligence Tech. Optimized Solution for Machining of Advanced-Material with Ultrasonic-Assisted Machining Module +886-4-2285-0838 sales@hit-tw.com ←Back