Ultrasonic machining

An ultrasonically vibrating machine consists of two major components, an electroacoustic transducer and a sonotrode, attached to an electronic control unit with a cable.

[4] Machining time depends on the workpiece's strength, hardness, porosity and fracture toughness; the slurry's material and particle size; and the amplitude of the sonotrode's vibration.

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

Brittle materials fail by cracking mechanics and these high stresses are sufficient to cause micro-scale chips to be removed from its surface.

[7] While time spent machining and surface roughness decrease with CUSM, the entrance profile diameter is slightly larger than normal due to the additional chemical reactivity of the new slurry choice.

In order to limit the extent of this enlargement, the acid content of the slurry must be carefully selected as to ensure user safety and a quality product.

[7] Materials that are commonly machined using ultrasonic methods include ceramics, carbides, glass, precious stones and hardened steels.

[5] As advanced ceramics become a greater part of the structural engineering realm, ultrasonic machining will continue to provide precise and effective methods of ensuring proper physical dimensions while maintaining crystallographic properties.[speculation?]

The absence of distortion is due to no heat generation from the sonotrode against the work piece and is beneficial because the physical properties of the part will remain uniform throughout.

[9] Because ultrasonic vibration machining is driven by microchipping or erosion mechanisms, the material removal rate of metals can be slow and the sonotrode tip can wear down quickly from the constant impact of abrasive particles on the tool.