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• Ultrasonic Vibration: High-frequency ultrasonic vibrations (typically in the range of 20 kHz to 60 kHz) are applied to the tool, which is then (Source of images:
transferred to the workpiece through the slurry. https://www.linkedin.com/pulse/ultrasonic-
• Abrasive Action: The ultrasonic vibrations cause the abrasive particles to impact the workpiece surface, inducing micro-chipping and erosion. machining-alex-babu-kurisinkal)
The combined action of the abrasive particles and the vibrations results in material removal.
• Slurry Flow: The slurry carries away the removed material and helps maintain a consistent machining process.
• Control and Monitoring: Parameters such as ultrasonic frequency, amplitude, and slurry composition are carefully controlled to achieve the
desired material removal rate and surface finish.
Ultrasonic machining has several advantages:
• Effective for machining hard and brittle materials that are challenging for conventional methods.
• Minimal thermal and mechanical stresses, making it suitable for delicate workpieces.
• Capable of machining intricate and fine features.
• However, ultrasonic machining also has limitations:
• Lower material removal rates compared to some traditional machining processes.
• Limited to relatively small workpieces due to the size of the ultrasonic equipment.
• Tool wear and maintenance due to the abrasive nature of the process.
Ultrasonic machining is used in various industries, including electronics, optics, aerospace, and medical device manufacturing. It is applied to
produce components like microelectronics, precision optics, semiconductor components, and ceramic cutting tools.
Electronic Electronic Beam Machining (EBM) is a non-traditional machining process that utilizes a focused beam of high-energy electrons to remove material
Beam from a workpiece. EBM is similar in concept to other non-traditional machining methods like electron beam welding and laser cutting, but it is
Machining specifically used for precise material removal and machining operations.
In EBM, a beam of electrons is accelerated to high speeds using an electron gun. The accelerated electrons form a focused beam that is directed
(EBM)
towards the workpiece. As the high-energy electrons strike the workpiece's surface, they transfer their energy, leading to localized vaporization
and material removal through a combination of melting, vaporization, and ionization. The process is conducted in a vacuum chamber to prevent
electron scattering and maintain control over the machining operation.
Key features and steps of the electronic beam machining process include:
• Electron Gun: An electron gun generates a stream of high-energy electrons, forming an electron beam.
• Workpiece Setup: The workpiece is placed in a vacuum chamber, and the electron beam is directed towards the machining area.
• Material Removal: The focused electron beam strikes the workpiece's surface, causing localized vaporization and material removal.
• Vacuum Environment: The vacuum environment helps maintain control over the electron beam and prevents scattering or interference from
the surrounding air.
• Control and Monitoring: Parameters such as electron beam current, voltage, and focus are carefully controlled to achieve the desired material
removal rate and accuracy.
EBM has several advantages: (Source of images:
• High precision and accuracy, allowing for intricate shapes and fine details. https://entiinnovations.wordpress.com/2014/
• Minimal heat-affected zone and thermal stress, making it suitable for delicate workpieces. 05/05/electron-beam-machining-ebm/)
• Can be used on a wide range of materials, including metals, ceramics, and composites.
However, EBM also has limitations:
• Limited material removal rates compared to some traditional machining processes.
• The vacuum requirement can be a logistical challenge and affect the overall process.

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