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Questions and Answers
What is the main component of the slurry used in Ultrasonic Machining (USM)?
What is the main component of the slurry used in Ultrasonic Machining (USM)?
What type of tool is typically used in Ultrasonic Machining (USM) to vibrate against the workpiece?
What type of tool is typically used in Ultrasonic Machining (USM) to vibrate against the workpiece?
What are some common materials used for making the tool in Ultrasonic Machining (USM)?
What are some common materials used for making the tool in Ultrasonic Machining (USM)?
Why is the concentration of abrasives in water important in Ultrasonic Machining (USM)?
Why is the concentration of abrasives in water important in Ultrasonic Machining (USM)?
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What type of work materials are suitable for Ultrasonic Machining (USM)?
What type of work materials are suitable for Ultrasonic Machining (USM)?
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In USM, what shapes can be achieved with the machining process?
In USM, what shapes can be achieved with the machining process?
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What is the purpose of using smaller openings in Water Jet Cutting on thinner materials?
What is the purpose of using smaller openings in Water Jet Cutting on thinner materials?
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Why is it generally desirable for the standoff distance in Water Jet Cutting to be small?
Why is it generally desirable for the standoff distance in Water Jet Cutting to be small?
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What is the typical range for feed rates in Water Jet Cutting depending on the work material and its thickness?
What is the typical range for feed rates in Water Jet Cutting depending on the work material and its thickness?
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Why are polymer solutions preferred as cutting fluids in Water Jet Cutting?
Why are polymer solutions preferred as cutting fluids in Water Jet Cutting?
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What is a significant disadvantage of Water Jet Cutting when it comes to cutting brittle materials like glass?
What is a significant disadvantage of Water Jet Cutting when it comes to cutting brittle materials like glass?
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Which material is commonly used to make nozzles for Water Jet Cutting?
Which material is commonly used to make nozzles for Water Jet Cutting?
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Study Notes
Mechanical Energy Processes
- Ultrasonic Machining (USM) uses abrasives contained in a slurry of water and abrasive particles to wash away chips.
- The slurry consists of a mixture of water and abrasive particles such as boron carbides, aluminum oxide, silicon carbide, boron nitride, and diamond.
- The tool, made of soft steel or stainless steel, vibrates at a high frequency (20,000 Hz) and low amplitude (0.076 mm) to remove material.
- The tool oscillation is perpendicular to the work surface, and the tool is fed slowly into the work.
- The concentration of abrasives in water ranges from 20% to 60%, and the less viscous the slurry fluid, the faster it can carry away chips.
Advantages of USM
- Any material can be machined regardless of their electrical conductivity.
- Good surface finish is obtained with little or no surface damage.
- USM is a non-thermal process and is not dangerous.
Disadvantages of USM
- Material removal rates are low.
- The depth of the hole is limited to the size of the tool.
- Tool wear is high, and sharp corners cannot be generated.
- High power consumption is required.
Applications of USM
- USM is suitable for hard, brittle work materials such as ceramics, glass, and carbides.
- USM is also successful on certain metals, such as stainless steel and titanium.
- Shapes include non-round holes, and "coining operations" can be performed.
Water Jet Cutting (WJC)
- WJC uses a fine, high-pressure, high-velocity stream of water directed at the work surface for cutting.
- The nozzle diameter is 0.1-0.4 mm, and smaller openings are used for finer cuts on thinner materials.
- Pressure: up to 400 Mpa, and jet velocity: up to 900 m/s.
- The standoff distance, the separation between the nozzle opening and the work surface, is 3.2mm.
Advantages of WJC
- No crushing or burning of the work surface.
- Minimum material loss because of the narrow cut slit.
- No environmental pollution.
- Easy automation of the process using CNC or industrial robots.
Disadvantages of WJC
- Not suitable for cutting brittle materials (e.g., glass) because of their tendency to crack during cutting.
Applications of WJC
- Used to cut narrow slits in flat stock such as floor tile, food, composites, plastic, carpet, leather, and cardboard.
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Description
Explore the process of Ultrasonic Machining, which involves high-velocity abrasives vibrating against the workpiece to remove material. Learn about the slurry mixture of water and abrasive particles used and the tool materials involved in this mechanical energy process.
